1986 O'Day 272 Window Question

[rlpeeples88]

I believe I have a small leak in one or more of my windows on port and starboard side. How and the world do I get them off my boat to replace with new ones? They're glued onto some gelcoat or something. See attached pictures. PO tried to put temporary caulk on outside of windows. That's what you see in the pics.

[stam22]

Rudy at D&R Marine sold me replacement windows for my O'Day, and gave me complete verbal instructions on how to install. He also sells two different color sealants.

[rlpeeples88]

Yeah I already know about Rudy and D&R. However, I don't want to replace the windows yet. I just want to rebed them. So I'm wondering if anybody could tell me how they got theirs off.

[JKCatalina310]

If you make a small hole, you can put stainless wire or string through the hole. Then you can work it back and forth like dental floss. That should break the seal without damaging the window.

[Faster]

JKC's method ought to work... you may be able to get under one corner and start cutting the sealant that way. Use a small gauge non-wound guitar string maybe, and put small dowels on each end to hold onto (think garrotte ).

A thin but stiff putty knife, a hammer and a LOT of patience might get you going too. But I think that either of these methods is not necessarily guaranteed to do no damage to the windows. Acrylic is not that expensive so replacing them in the event that you crack one is not the end of the world, and planning to do so does somewhat simplify the removal process.(ie if you're not worried about salvaging the old portlights)

We've had great success with Dow Corning 795 as a sealant/adhesive in that situation when it comes to rebedding. Be sure to drill any screwholes considerably oversize to allow for the large difference in expansion between acrylic and fiberglass.

[rlpeeples88]

Thanks for the replies. The steel wire dental floss method is very clever. I hadn't thought of that. And I've tried the hammer and chisel method. That gets me nowhere fast.

But thanks for the responses. It gives me something to think about.

[cspaniel]

rl, try a pastry spatula, I used it to do the same in my 322, was very easy and didn't scratch the windows or the fiberglass. Then rebed with Dowcornig 795, overall time-consuming but very easy.
Ab

[WouldaShoulda]

If the seal is that tight, how is it leaking??