[Rhodes22-list] Window replacement update - done

[The Rhodes 22 Email List]

This is incredibly nice. I've thought about doing this but don't have near
the courage yet. I'm still learning to do decent gel coat.

Larry Allen
Makai
Sarasota FL

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From: rhodes22-list-bounces at rhodes22.org
[mailto:rhodes22-list-bounces at rhodes22.org] On Behalf Of The Rhodes 22 Email
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Sent: Saturday, June 06, 2015 9:30 PM
To: 'The Rhodes 22 Email List'
Subject: [Rhodes22-list] Window replacement update - done

So I screwed up my courage and installed the starboard window today. In the
end I was satisfied with the outcome but along the way I thought at one
point that I had an unmitigated disaster on my hands.

I applied the double-sided tape to the cabin leaving 1/2 inch between the
tale and where the edge of the acrylic panel for the sealant, applied the
sealant (see picture attached) and pressed on the glass. I had my wife help
by anchoring the bottom aft corner in alignment with the moulded in ledge
and then I wrapped the glass into place going forward. When I got to the
front I checked back and discovered that my wife thought she was supposed to
place the glass on the top of the ledge instead of on the face of the cabin
side so the whole thing was badly misaligned and the aft part of the window
was not even touching the cabin side - my nightmare scenario. 

Lesson one, don't assume that your helper understands what you intend.

Contrary to what I expected, I was able to pull the glass off and reposition
it properly. It took a lot of force but it did separate cleanly. Fortunately
I had pressed the tape firmly onto the cabin using a roller before I applied
the sealant but I had not yet pressed the glass into the tape firmly. The
second attempt, aided by some colourful language did the trick.

Lesson two: The tape is not entirely unforgiving when pressure has not been
applied. I was very very lucky this time.

Lesson three: The tape is amazingly tenacious. Once pressed into place I did
not need to use the clamps that I had devised to hold the glass in place
while the sealant cured.

Lesson four: A white boat with black sealant is a potential disaster. I
masked back 2 feet from the edge of the glass and changed my plastic gloves
repeatedly but I still had black goo everywhere - including my face.
Fortunately, as long as you get to it before it cures it can be removed. For
the port side I will increase the area that I mask off and have a place away
from the boat where I can put tools down.

Lesson five: Removing the protective covering from the inside after the
glass was installed was easy. I could pull up the edge with my fingernail
and then pull the paper off in one piece. Having painted over the paper I
had worried that it might be difficult to peel the paper off but the paint
turned out to have no effect.

It feels like a solid installation but only time will tell. Hopefully it
won't spring off overnight.

Now that I have gone through this once, hopefully the port side will go
smoother and with lest anxious anticipation.

Given the cost of ports and the problem of installing them so they don't
leak, I am satisfied with this fix - about $300 total for both sides. The
bonus is that the window openings are considerably larger than the original
ports.

I have attached a picture of the finished product.


Graham
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