Refurbishing Aluminium windows - advise sought.

[chasroberts]

Due to age/Med sun or whatever one of my saloon windows now has the waterproof abilities of a sieve so it is time to sort it out. The windows are made up of a double track extruded aluminium, in which 6mm plastic is fixed using a rubber seal. I have removed the window which was a major job in itself as it seems to have been stuck in with a really strong mastic/adhesive.

The rubber in the seals is completely shot hence the leak. Track width is approx 9.5mm and depth about 14mm. I have found this rubber seal:

http://www.woolies-trim.co.uk/p-1774-rubber-extrusion.aspx

which I think looks OK, even though it's slightly larger than the track, I assume I will be able to compress it into the track when reassembling. From reading other threads I think I am looking for 6mm polycarbonate plastic as the old stuff is scratched and starting to craze over. So my questions really are as follow:

1. Am I correct in thinking that I need polycarbonate for the replacement window glass(?) or should I be looking for something else?

2. Will the 10mm rubber extrusion be OK?

3. Do I need anything else to weatherseal the window besides the compressed rubber ie a mastic bed of some sort in addition.

4. Which is the best mastic to reseal the window frame into the coachroof.

Any other thoughts on the subject would also be really appreciated.

Many thanks in advance.

Chas

 

[Tranona]

Polycarbonate is fine but you could also use glass. Suggest rather than bodge the seals, speak to a specialist like Eagle Boat Windows or Hadlows as they will probably have the correct seals. They will also sell you butyl tape to attach them to the coachroof rather than mastic. They will also rebuild your windows for you but that may not be convenient.

 

[VicS]

Look at Seals+Direct for your rubber/ plastic seals... I'd not bank on being able to compress one which is too large. http://www.sealsdirect.co.uk/

Your choice acrylic or polycarbonate. Polycarbonate is virtually unbreakable but acrylic better on most other counts

Avoid sealants with solvents unless stated to be suitable for plastic glazing but if properly installed you should not need sealant as well as the rubber seal.

some like butyl tape to seal the frames to the supersructure others like a butyl mastic http://www.arbo.co.uk/

Sikaflex sealants are good but next to permanent

A polysulphide ?? or a copolymer such as CT1

Other links for materials and advice

Hadlow Marine http://hadlo-43547-001.dsvr.co.uk/

http://www.eagleboatwindows.co.uk/

http://www.seaclear.co.uk/

http://www.projectplastics.co.uk/

http://www.ukplasticfabrication.co.uk/

http://www.sunlightplastics.co.uk/

 

[Keith-i]

Topical subject for me. I've got a persistent leak on one of my windows which I've yet to sort. I bought replacement flock channel for the sliding section from Hadlow Marine.

What are the options for bedding fixed panes into the ally frame? Would it be butyl mastic? I bedded the frame onto the coach roof with silicone sealant which is nice and flexible but still removable if needed. Maybe butyl tape would be better.

 

[vyv_cox]

I assume you are in Greece? All eight of my windows are currently in Athens being refurbished with new glass and seals. I am assured that this company is first class and will provide a long-term solution to the problems of differential thermal expansion. Innyour type of window polycarbonate may not be ideal as its coefficient is high. The glass is working out at around €20 per window. Can provide contact details if required.

 

[chasroberts]

Many thanks to all for your thoughts. Plenty of research still to do by the look of it! I have updated location info to the South of France so the Athens thing is a bit of a long shot Vyv but thanks anyway. It is easier to find glass here than any sort of plastic so that may be the way to go. Appreciate it should be toughened glass but is there a particular type? I have glass windows in the forward facing windows of the deck saloon but plastic in the sides.

Any more thoughts would be gratefully appreciated.

Chas

 

[Rigger Mortice]

Toughened glass is much the same wherever you get it from. The only issues are how thick it is, whether or not you want it to match up a tint on other windows and if it is flat. It can take a slight bend but a full curve would need to be specially made. When you fit toughened glass remember that the edge is delicate.....you can hit the face with a hammer and it won't break (within reason!) but a gentle tap on the edge and the whole thing can shatter very easily.

 

[PabloPicasso]

CT1 is the same as the cheaper and readily available in builders merchants Tek7. My preferred sealant

 

[vyv_cox]

Usual advice is to bed the frames on a non-setting butyl mastic, Arbomast or similar. I have used it once, for a perspex window on another boat, and found it to be excellent. Used the same stuff to set the sink in my worktop at home, worked very well. Will advise what Athens send me in a day or two, ferries permitting.