[Rhodes22-list] Replaced Windows/Companionway Door Panels

[The Rhodes 22 Email List]

You didn't sign your message so I am not sure who I am responding to.

Your ports look like a great improvement to me and should give you ports
that should never leak and at the fraction of the cost of new ports. I am
planning to do as you did with the companionway door except that I will not
be using wood trim. Yours looks terrific and I am now keen to do it. The
only bright work on my boat will be the tiller. I will either use aluminium
or composite lumber for the trim - probably the latter.

I also toyed with the idea of shaping the acrylic using heat but I would
need to build an oven that would hold pieces over 5'long and I was worried
that I would just ruin the piece. In theory you can shape the acrylic with a
heat gun but from what I read it is very difficult to get an even bend on a
large piece. As it turned out the acrylic took the shape very well and the
tape held it firmly in place.

Graham 

-----Original Message-----
From: rhodes22-list-bounces at rhodes22.org
[mailto:rhodes22-list-bounces at rhodes22.org] On Behalf Of The Rhodes 22 Email
List
Sent: June-09-15 9:05 PM
To: The Rhodes 22 Email List
Subject: [Rhodes22-list] Replaced Windows/Companionway Door Panels

Graham, nicely done.  Wish mine came out as nice as yours.

Everyone else, this past weekend I replaced my windows and my companionway
door.  I used the 3M VHB 4991 double sided tape and Dow Corning 791 silicon
as Graham suggested for the windows, and I can attest their wonderfulness.

I identified a nice way of generating pressure on the windows for the gasket
to seal.  I used two dent puller suction cups from inside, and wooden wedges
through the handle to maintain pressure.  Not sure if this would help with
larger windows like Graham's.

I ended up using 3/16" bronze plexiglass for the windows and 3/8"
plexiglass for the companionway.  1/8" seemed too flexible for the size,
though in retrospect I think it would have been fine since the windows are
smaller, and the tape adhesion would have been simpler with a more flexible
pane.  http://www.eplastics.com/Plastic?search=Bronze2370

The 3M VHB 4991 tape, I got in 1" width, boxed out the frame, and used a
razor blade to cut off excess after window installation.  Having the 1"
tape gave me a solid taper, and the silicon will provide a good waterseal on
the tape (hopefully).

I toyed with the idea of oven heating the plexiglass to increase
flexibility, but decided against it due to the size difference, and fear it
would break the plexiglass (since the sheer strength of the 3M VHB tape is
insane).

Sadly, my windows & door looks nicer than the boat, and its unbalanced now.

Photos:
1) Previous Owner's pine/polyurethane companionway door panels.
2) New window close up
3) New window & old window side by side.
4) My replaced companionway door panels.
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