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Catalina/Capri 25/250 Sailor's Forums

Catalina 25 Specific Forum

Window removal and reseal

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slim
Navigator

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USA
113 Posts

Initially Posted - 02/15/2016 : 14:46:58

Hi everyone

I am starting on the job of removing and resealing my windows on the 1978 c25 fin keel. After 38 years it was interesting to see just what had been done by the PO in attempting to keep to the water out. I think if you can imagine it then it probably was done. I found plumbers putty, butyl tape, 5200, RTV red, silicone and several mystery items. One window in particular was glued in so tight i did some damage getting it out but it is repairable.

I am getting ready to order the reseal kit from CD and was wondering if any of you might have some thoughts on this job. Just so you know there is some core wood delamination and i may be required to remove some and fill with epoxy and thickener as suggested by Don Casey in his book (Hull and Deck Repair). Posting some photos so you can get an idea of where i am at. Thanks in advance for your advice and help.

Slim

Removal
Windows finaly out after much frustration

wood core damage

1978 - C25 - standard rig - Fixed keel #1040

Bladeswell
Captain

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USA
490 Posts

Response Posted - 02/15/2016 : 16:43:29

Hi Slim,
As you may know, my boat is a 1979 and bought as a restoration project. When I bought her back in July, the PO had removed all of the ports in preparation of seal repair/replacement.
After some reasearch, I found that most manufacturers no longer use "framed ports". That includes Catalina. Most have now gone to frameless ports. With the original framed ports, you have three different places that can leak so once a leak develops itcan be tough to determine where the leak is coming from.
you have the outside frame to cabin seal and two different rubber seals inside holding the glass. When you go frameless, there is only one place it can ever leak. The sealant I used, and to my understanding Catalina now uses is Owens Corning 795. This stuff is used to install huge sheets of glass or acrylic in skyscrapers with no fasteners. I used fasteners in my install only because I didn't figure out a way of keeping them in place while the sealant setup. As you will see in the pics, I failed to use enough sealant on my first attempt so I had to remove that one and do it again using more.
After that, all went well and I was done in one day. Also with the original framed ports, Catalina used glass. and thin glass at that. Not very safe in my opinion. Most prefer acrylic, but I chose poly carbonate.

Bladeswell

C25 TR FK Hull #973 1979 L-Dinette. So.Cal.

Edited by - Bladeswell on 02/17/2016 19:53:11

OLarryR
Master Marine Consultant

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USA
3418 Posts

Response Posted - 02/16/2016 : 05:16:55

In regards to frameless ports/windows, many years ago I discussed and then purchased a replacement port from Catalina (the mfr). They also provided me the Catalina Drawing that illustrates the install. It also references the Dow Corning 795 mentioned in the above posting. This info was on my website located in the bottom left corner - a link. I attached the link below. As it turns out, the port I was going to replace because of a vertical crack in it, I had temporarily put a bead of 3M sealant on it awaiting the replacement port. But the crack does not leak and the sealant is intact and so I have procrastinated going forward with installing the new port for many years now. I just have the new port laying in my VBerth. Maybe one day, I'll get around to installing it.....
http://catalina25.homestead.com/WindowReplacement.html

Larry
'89 Robin's Nest#5820, Potomac River/Quantico, Va
http://catalina25.homestead.com/olarryr.html

Bladeswell
Captain

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USA
490 Posts

Response Posted - 02/16/2016 : 07:34:25

Hello again,

I followed your link and wished I had found it before my install. A great idea with the wooden wedges and weights. It would have provided a better looking finished job. For anyone who chooses to use screws for this job like me, I should have mentioned that you need to drill the holes in the acrylic/poly carbonate two sizes to big in order to accommodate expansion and contraction due to variations in weather conditions.
I bought the material and did the cutting myself. Cost of $172 bucks for all six. I made them 1 inch bigger all around than the port openings as I wanted plenty of seal area. I'm not sure what size of Dow 795 Catalina provides for the install but I bought two regular caulking gun sized tubes for the entire job and had a little left over. Even after my first fail and re-do.

Bladeswell

C25 TR FK Hull #973 1979 L-Dinette. So.Cal.

OLarryR
Master Marine Consultant

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USA
3418 Posts

Response Posted - 02/16/2016 : 11:04:50

Catalina Yachts custom made the port with beveled edges to the traced outline I provided. I cannot recall the exact cost but I believe it was around $70 back in 2008. I checked out the port and would be an exact fit but as I indicated, I put off the install since my existing port does not leak - The sealant I used is intact and basically waterproofed the crack which is noticeable but not hideous...well you get used to it.

Catalina Yachts recommended not drilling the screw holes and utilize the sealant only since once it sets up they felt it was sufficient and that is the way they install ports these days or at least back in 2008. However, you only paid $172 for all six ports, which is excellent and you have the satisfaction that you were able to make all the ports yourself !

Larry
'89 Robin's Nest#5820, Potomac River/Quantico, Va
http://catalina25.homestead.com/olarryr.html

Rainwater
Deckhand

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22 Posts

Response Posted - 02/17/2016 : 15:02:01

I resealed my windows on my 78. I found the almost exact rubber that surrounds the glass for 30 bucks at a local rubber supplyb house. I used buytal tape to reseal frames to the boat. I had to replace and epoxy new core, mine was all roud out. Your right about it being interesting in what the PO used to seal.

"Lisa Rene"-1978 C25

Stinkpotter
Master Marine Consultant

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Djibouti
9058 Posts

Response Posted - 02/17/2016 : 15:55:09

Guy (Bladeswell): If you put "carriage returns" (Enter key) between your images in your post, they'll appear vertically so as not to stretch this whole thread out so we need to scroll it sideways to view it.

Dave Bristle
Association "Port Captain" for Mystic/Stonington CT
PO of 1985 C-25 SR/FK #5032 Passage, USCG "sixpack" (expired),
Now on Eastern 27 $+!nkp*+ Sarge

Bladeswell
Captain

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USA
490 Posts

Response Posted - 02/17/2016 : 18:38:17

Hello Again,
Thanks Dave. I didn't know why it was doing that. Now that I know what to do my posts in the future will be neater. Thanks again.
Bladeswell

C25 TR FK Hull #973 1979 L-Dinette. So.Cal.

slim
Navigator

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USA
113 Posts

Response Posted - 02/17/2016 : 19:06:11

quote:
Originally posted by Bladeswell

Hello Again,
Thanks Dave. I didn't know why it was doing that. Now that I know what to do my posts in the future will be neater. Thanks again.
Bladeswell

Ya I was wondering about that my self. I think you can go into edit and do it even now if you want.

Slim

1978 - C25 - standard rig - Fixed keel #1040

Bladeswell
Captain

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USA
490 Posts

Response Posted - 02/17/2016 : 19:57:02

Woo hoo,
Thanks Slim and Dave. I fixed it. Now I will go back to some of my older posts to fix those as well. We don't just learn about boats here....lol. Thanks again.

Bladeswell

C25 TR FK Hull #973 1979 L-Dinette. So.Cal.

slim
Navigator

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USA
113 Posts

Response Posted - 02/21/2016 : 19:23:32

The window soga continues, who ever said that this job was like living a nightmare was not to far off,

It really does require a maximum amount of patience and will, also a spear helper

is absolutely necessary. I am using the sealant supplied by CD for the window seal and butyl tape for the seal of window frame to cabin all very messy

and frustrating

to work with. None the less i am down to the last window

now and have run out of tape so reordered and am now waiting for it to arrive so that i can finish the job hopefully successfully.

Will post completion photo when done.

1978 - C25 - standard rig - Fixed keel #1040

Edited by - slim on 02/21/2016 19:26:18

Stinkpotter
Master Marine Consultant

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Djibouti
9058 Posts

Response Posted - 02/21/2016 : 20:20:08

quote:
Originally posted by slim

,,,this job was like living a nightmare

NO! It's living the DREAM! You're a YACHT OWNER! Just not the dream of winning Powerball...

Dave Bristle
Association "Port Captain" for Mystic/Stonington CT
PO of 1985 C-25 SR/FK #5032 Passage, USCG "sixpack" (expired),
Now on Eastern 27 $+!nkp*+ Sarge

Edited by - Stinkpotter on 02/21/2016 20:21:16

islander
Master Marine Consultant

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USA
4013 Posts

Response Posted - 02/22/2016 : 07:23:29

quote:
NO! It's living the DREAM!

I have to disagree Dave, Living the dream would be to win the powerball then buy a brand new boat without any problems to fix. And if you did have problems you just hire someone else to fix them!

Now please pass the Caviar...

Scott-"IMPULSE"87'C25/SR/WK/Din.#5688
Sailing out of Glen Cove,L.I Sound

Edited by - islander on 02/22/2016 07:24:28

Bladeswell
Captain

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USA
490 Posts

Response Posted - 02/22/2016 : 08:52:48

Hello Again,

You've probably all heard this one before... BOAT: break out another thousand.... LoL.

Bladeswell

C25 TR FK Hull #973 1979 L-Dinette. So.Cal.

slim
Navigator

Members Avatar

USA
113 Posts

Response Posted - 03/04/2016 : 12:59:52

I finally got this job completed and i am so glad of it. If you are looking at the pictures you will see that i left tabs on the spacing rubber for the next few weeks in case of shrinkage.

1978 - C25 - standard rig - Fixed keel #1040

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