Window advice

Cardo

Cardo

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www.yacht-tinkerbell.co.uk
We are sorting out the two side windows on the deck saloon of our elderly Southerly as they leak like a sieve.
I have been in touch with Eagle Boat Windows and obtained a quote in relation to resealing the windows.

However, having taken one of the windows out, I've noticed they are perspex in an aluminium frame. The frame has seen better days and the perspex has some scratches in it.

The frame will need cleaning up quite a bit. I've done what I can do remove as much mastic as I can from this, but there are traces left. The seal between the frame and the perspex will also need quite a bit of cleaning up. The frame is also slightly bent from removing this from the boat, but I'm hoping it should just be a case of bending it back once it has been fully disassembled. I can't quite get the leverage with the perspex in place.

My question is this: What would be the best solution to sorting out the windows? Obviously, EBW will advise something once they've seen them, however what should I be contemplating?
I'm hoping the frames themselves are salvageable and simply need some TLC to get them looking better. I'm guessing the advice will be to get new pieces of perspex at the very least.

Without having seen the windows, can anyone provide some thoughts?
 
I had mine reglazed in tinted toughened glass - a fraction cheaper than Perspex and no more scratching or crazing. Of course this was not a DIY job. I had it done by Houdini who are near me. They make the windows for Southerlies. Might be worth a conversation.
 
I used Hadlow Marine to fix my aluminium framed windows. The frames are original equipment installed in 1974. The frames typically had areas of metal loss, holes and active corrosion.

Hadlow cleaned up the frames and filled the channel with a black sealant which the glass was embedded in. They have proved to be 100% water tight.

The original frames had the glass held in place on one side (the inside) with a double sided sticky tape and on the outside with an O ring. This method of construction meant that there was a significant air gap around the inside of the frame which trapped moisture.

Perhaps your frames are like mine, if so then the method used to refurbish them might be the complete filling with sealant.

Hadlow Marine Web Site I have no association with Hadlow Marine, except as a customer.
 
I replace S95 windows around 2005 and they were still fine 4-5 years later. I used the existing frames as they cleaned up quite well. I can probably give more detail after digging around in my old records.

1) Remove windows & dismantle at home
2) Fit temp covers (plastic sheet, ply, duct tape etc.)
3) Clean inside frames & abrade
4) Use old windows as templates to cut new ones
5) Cut lots of black polythene spacers, assembled each window roughly and cut spacers to a close fit.
6) Fitted masking tape all around new windows, just level with top of frame
7) Glued spacers in correct place (with window removed)
8) Fitted masking tape to outside of frame
9) Filled void with Arbosil 1094 (need to check this)
10) Built frame back up
11) Screwed together using S/S screws & Duralac
12) Trim excess sealant when set

This is a rough plan but I can probably get more detail. I remember that assembly was messy as the Arbosil was quite runny. I did assembled frames in 2 parts, base with side and top with other side. The 2 parts were mated together but I think I let the base section partially set first so I could turn it upside down.

Unfortunately, I've been cleaning out old PC files and think I may have deleted schematics and notes a few days ago (typical).
 
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