Join Date: Feb 2006
Location: Florida, US northeast
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I am in the process of replacing the ports in my Islander Freeport 41. After much soul searching I have decided to use 1/4 acrylic, just like the originals. I have searched the posts on this subject and the major issue seems to be expansion. The largest window is 40 inches long.
Lots of people have used butyl tape. Others swear by Sikaflex. I have used butyl a lot in the auto industry to affix trinkets, nameplates and such, and it is strong and lasts for years in the exposed environment of a car's outer surfaces. Others swear by Sikaflex. Everyone seems to agree, no silicone.
I have 22 windows to replace so I want to do it right the first time. Here's the current plan. I would mount them directly on the deckhouse with adhesive. The overlap of the original ports is 9/16 inches. I plan to increase this to 3/4 inches. Then apply Sikaflex primer to the outer 1 inch, both for priming and to provide a blackout strip. Following that, 1/4 inch in, would be a strip of butyl tape. Then apply the window to the deckhouse and mask the outline on the deckhouse. Finally, a bead of Sikaflex to fill the 1/4 gap.
Any comments would be appreciated. Compatibility of adhesives with acrylic, effectiveness of sealing, application method...all are fair game. Please let me know your experience.
Thanks, best regards and Merry Christmas,
Coral Gables, FL