Replacing the Fixed Port Windows

Replacing the Fixed Port Windows on our Catalina 34

The fixed port windows on both sides of the boat are most certainly original, so now 34 years old and are showing it.

The C34 forum has some great advice on the project to replace them.

The Port side aft window has an opening port for the bathroom and the Stbd aft window is actually split into two pieces but installed touching each other. In both cases, the new windows will be single piece and exclude the bathroom window opening. 

Supplies

3M VHB 1" Tape - Amazon

Dow Corning 795 Black Silicone Sealant - Grainger Industries

40 Grit Sand Paper

Acetone  

1/4" Acrylic 4 pieces
Prospect Plexiglas Plastics https://goo.gl/maps/XZKJo1M8mxR9rmAz6

836 NE 44th St, Oakland Park, FL 33334 

19545646820

• Port Side Forward 39x9 appx
• Port Side Aft 40x9 appx
• Stbd Side Forward 39x9 appx
• Stbd Side Aft 40x9 appx

Image showing Catalina 30 Window Install

The pic above shows the way that the windows are installed on another Catalina model. The concept is the same. However, my install will follow the concept shown by Andy of Boatworks Today (Here's a link to his video online)

Process

Plan is to do this job with a fellow Catalina 34 owner that keeps his boat about 1/4 mile from where we keep ours.

• Make cardboard template of each window (that's 8 templates for 2 boats)
• Get replacement windows made at the Plastics company
• Prepare new windows
• Trim 1" of protective cover from inside of windows
• Wipe rims with alcohol
• Fix (glue) temporary handle to outside of window for placement control
• Remove the old windows (have waterproof covering handy in case of rain)
• Clean window recess 
• Paint inside edge with black or white paint
• Paint fiberglass segment between galley window and aft cabin window (new window will be one piece)
• Apply 3M VHB tape to outside edge of window sunken area
• Trim tape to have round edges and very close joins
• Plant window into opening on outside using the temporary handle.
• Press from outside all the way around the window edges.
• Mask off the fiberglass around the window to minimize silicone spread
• Open Dow Corning silicone crimp end with pair of snipe nose pliers
• Apply silicone around window and fair with wet finger
• Peel off masking tape on outside
• Peel off protective tape on outside
• Peel off protective tape on inside

So, that's the plan.

I'll update this post as we make progress.