Monday, November 19, 2007

Another project done...Yippie

The windows are finally done. They were to be completed last week, but as everyone knows when it comes to dealing with boats they sometimes have their own agendas. All I know is that I know too much about lexan at this point. I did so much research on what is compatible, whats not. I figure after spending so much money on this stuff that I didn't want to ruin a piece by some stupid mistake on my part. So armed with knowledge we had headed down weekend before last to install the windows. Its hard to explain, but as you look at the boat you see the cutout for the window. As you look into the cutout you see the two layers of fiberglass. Inside the cutout the interior window frame mounts to the backside layer. This gives you a nice finished look from the inside. Not so from the outside, as you see the backside of the frame in the window opening from the exterior. That wasn't confusing at all was it? Previously the window was very dark and hid all the extra stuff going on behind the plexi. When we installed our lexan you could see the interior frame and the gap between it and the fiberglass. "Geeeeze, that's ugly." So we came up with the idea of boat striping tape to hide the gap and frame. We had also put a bead of caulk on the window before we installed it. So now we had a beautiful window with a framed out window opening and a bead of caulk under it. From the dock it didn't look bad. To us it looked like poo. Frustration was building as I just let the project sit the weekend as I racked my brain for solutions. Meanwhile Dirk had a list of other duties he wanted to get done. He removed the bow pulpit to fix and fill all the attachments. Looks like a previous owner had snagged on something or someone snagged his pulpit. The places it attached to the deck were semi loose. So Dirk removed the pulpit entirely and preceded to clean out and fill the holes. Apparently there was core rot and a lot of vacant space between the fiberglass. Not good if you want a sturdy pulpit. He is getting quite good working with epoxy. So after filling the voids it sat for a day and he re drilled and re bedded the pulpit. That babies not going anywhere now. So anyway, back to the windows. We decided that we would paint the backside of the windows to hide all the yucky stuff and give the window a more finished appearence.

This is the final product after we first attempted. Note white border of striping tape and windows see thru
Here is the window taped up for spraying. I also have the front of the window covered with plastic wrap to keep us from scratching them."
Here the window has been sprayed with a flat black paint.
Here Dirk is posing with the new window after the tape and plastic wrap removed.
New window installed
Here is the final product. New, clear, un-scratched, un-leaky windows. We are both happy with the results and have gotten some nice compliments from other people on the docks. Now, if I can just get enough time to finish my floors. Yes they are still in the process. Just a couple more coats and I am finished. Hopefully they get installed this weekend.


  1. Good, creative solution! I'm taking notes for when I tackle my windows.

    What exactly, are you doing about the core issues? One repair book I've seen suggests putting a nail bent a a 90 degree angle in a drill and clearing a space around the mounting hole and then filling with epoxy.

  2. ruidh,
    Dirk uses an allen wrench instead of a nail. He does it by hand and not with the drill. This way you have different sizes to work with.


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