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Catalina/Capri 25/250 Sailor's Forums

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Sealing Flush Mount Lexan Windows

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lcharlot
Master Marine Consultant

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Antigua and Barbuda
1301 Posts

Initially Posted - 10/16/2003 : 01:20:02

I hate to open this can of worms again, but it looks like I might go ahead with the cabin window replacement while I wait the two weeks for my parts shipment from SailNet to arrive. I have decided to replace all of the exterior nav light fixtures - which were horribly crazed from UV exposure - and the deck socket, which shattered into three pieces in my hand when I unscrewed the mast wire plug. I have removed all of the old fixtures, and obviously can't launch the boat until the new ones arrive and get installed. So, I might as well do the cabin windows while I wait. Anyway, what's the concensus for proper sealant for the late-model Catalina 25/250 Lexan cabin windows? I have researched this on some of the other Catalina web sites, and most often it seems like BoatLife LifeSeal (the combination silicone/polyurethane goop), is mentioned for rebedding both the old-style aluminum windows and the new style frameless windows. Has anyone been able to find out what the Catalina Factory uses to mount the windows on new boats? I have tried twice to contact Catalina with this question and they have not responded with either an e-mail or phone call. All I can say is that whatever they use is extremely adhesive, like 5200, as I have not been able to pop out the old windows, pushing as hard as I can from the inside. However, I have read that 5200 and PolySulfide both should not be used on Lexan as they chemically attack the plastic. So what the heck did the factory use? If necessary, I am prepared to attempt to cut the sealant with a sharpened putty knife, working from the inside, but am understandably worried about damaging the sealing surface with such an aggressive move. Any ideas?

Larry Charlot
Catalina 25WK/TR Mk. IV #5857 "Quiet Time"
Folsom Lake, CA

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atgep
Master Marine Consultant

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1009 Posts

Response Posted - 10/16/2003 : 06:20:54

I work with aircraft parts that are sealed with a sealant that makes 5200 look like butter!. Anyone with avation maint experience knows what proseal is all about. Anyway, the least destructive way would be using an exacto knife to cut in from both sides. Once the sealant is mostly cut start with one corner and start working it from there. I have found that taking the time to cut the sealant is 90% of the work. An exacto knife has a very small gage blade and is pretty safe. A razor blade would work but one slip-up and you might wind up meeting a male nurse somewhere!!!I have used a rubber sledge hammer on aircraft windshields that were a little oversealed.HEHE. Good luck.

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dlucier
Master Marine Consultant

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Virgin Islands (United Kingdom)
7583 Posts

Response Posted - 10/16/2003 : 08:24:16

As to removing the old surface mount windows, I read a tip once about using fishing line to seesaw cut through surface mount deck hardware. Maybe you could use a similar technique to cut the sealant that is holding in your windows.

<img src="http://www.catalina25-250.org/c25sm.gif" border=0>Don Lucier<img src="http://www.catalina25-250.org/c25sm.gif" border=0>
<img src="http://im1.shutterfly.com/procserv/47b2d904b3127cce9f7cd9ffdf1d0000003010" border=0>
North Star SR/FK

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Notice: The advice given on this site is based upon individual or quoted experience, yours may differ.
The Officers, Staff and members of this site only provide information based upon the concept that anyone utilizing this information does so at their own risk and holds harmless all contributors to this site.