[Rhodes22-list] Replaced Windows/Companionway Door Panels

[The Rhodes 22 Email List]

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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