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Old 03-24-2012
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Replacing Leaky Windows

Apologies if this post has been made. I searched, but it seems as though it hasn't been covered in the manner I'd like to read. If it exists you may refer me to it.

My two priorites are eliminating leaks, and doing so as cheap as possible. Here is are my initial thoughts going into this project, I'm sure you guys will have some insight and opinions to help make this project more successful.

Through research I think I've narrowed down window material to either Lexan (polycarbonate) or Pexiglass (acrylic). Initally I was leaning towards polycarbonate because I was under the impression it would be easier to cut-to-shape with a fine tooth blade and a jigsaw. Is that the case ? I intend to do as much as possible myself, but would obviously conceed to the pro's if it otherwise means wasting material by chipping and breaking. But I also like the idea of a more scratch resistant material like acrylic if it's possible to cut myself. According to research it seems both can be cut by the DIYer. Can anyone recommend a supplier where I can get sheets of either material ?

Once making my mind on a material, I want to use the old windows as templates and make new oversized windows that I will lay in place and drill through the deck to secure using a silicone based compund to serve as a gasket. I'm aware of both materials tendancy to expand and contract so I was thinking I would oversize the drill holes for the screws to allow expansion and use rubber washers. I plan to use silicone compound as opposed to polyureathane to water seal the edges inside and out (I read in a Don Casey article, LifeSeal, a silicone/polyureathane mix, would work well for both seal and adhesion, but the permanence of Polyureathane makes me nervous even if mixed with silicone).

That's it. I'd love to have tinted glass, but feel like the darkness might add to the expansion problem. Do you agree ? Please share your wisdom.

Thanks all.
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