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Meat Popsicle
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Discussion Starter · #1 ·
Howdy

I got myself in a pickle without an exit strategy. The windows in my newport 30 were leaking so i pulled them out and pulled the glass out of the frame. The rubber gasket that ran between the outside of the window and the glass had hardened and shrunk some.

I'm left with the problem of how to bed glass in the aluminum channel. Going into this i thought butyl tape was the answer to all life's problems but there's scarcely a mention of it for this application outside of bedding automotive windshields.

Here's what i pulled out. Notice the L-shaped gasket, the channel on the right is where the glass goes.


My question is, what do i use to bed the glass to the aluminum? Where can I get some?

One possible solution, someone sent me a picture of a channel he ordered from catalina direct. Mine's a newport and the cross section is a U instead of L but it looks good. Think it will work?

Catalina Direct: Aluminum Window Reseal Kit C-30, C-36

Whenever I search for solutions to this problem I invariably end up finding a guide on how to throw away the aluminum frames and bolt on lexan. From where i stand, I understand the motivation completely. I'd consider cutting some myself but the surface is slightly bowed and looks like I would have to bend it.

What do i do? Is there someone in the annapolis area that carries appropriate window channels? Barring that, is there someone who cuts lexan windows?
 

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Telstar 28
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First, glass doesn't shrink...

Second, I don't see any reason why you couldn't use butyl tape to bed the glass into the channel. Of course, better photos would help make identifying the problem and coming up with a solution a lot easier. :)
 

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Don't worry bunny - your statement was correct - you just used too many syllables for Dog.
 

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A photo of the whole frame would be helpful. Butyl tape is too sticky to slid the glass along it... so if that's how you'd have to get the glass into the channel, it probably won't work very well. Also, how does the frame mount to the hull?? A photo of that would be helpful...unlike smacky...
 

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I have a newport 28 with window frames and gaskets that appear to match your photos. After a bit of searching I was able to locate a gasket at a local window shop in Buffalo that appears like it will work. I had to make new spacers for the glass because it was causing alittle deformation of the gasket. Did a leak test with the window horizontal using a preasure washer and standing water and no water made it past the gasket into the channel. This weekend will install the windows back on the boat. I can give you the part number and phone number of the place, they should be able to send you a sample.
 

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Meat Popsicle
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Discussion Starter · #8 · (Edited)
AKWNY, sounds great, any bit of information is helpful. What did you use for spacers? Oh and welcome to Sailnet.

SD, the frames only come apart at the place i photographed. They do not break into two pieces, they must be pried open and based on how hard it was to get it out, putting it back in will certainly involve a lot of sliding and profanity, so that probably rules out butyl tape then.

What on earth do i use to clean the frame?
 

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Yup... Butyl tape would make that a nightmare... :)
 

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The spacers were made out of delrin (used a tablesaw).

I don't have the receipt with me, so later this evening I will post the part number for the gasket.

I will try to get some photos of the original gasket, the new gasket, the original spacers, and the new spacers.

Once everything is cleaned up it just slides together.

I found the hardest part was geting the window frames out of the boat. I plan on using butyl tape to mount the frames to the boat.
 

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Hum, glass problem.

Take all parts to the experts, a glass shop.

The shop has catalogs of stuff you will never see and problems you will never have.

Just hand the parts to them and let them do what they do best.
 

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I am not sure if you are still looking for this or not. I did this same project over the winter, I found the gasket at a hardware store selling for a few cents a foot. They had various sizes. I suggest you take the old one to any hardware store, they should be able to match it.
 

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Meat Popsicle
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Discussion Starter · #14 ·
didn't find it at lowes
called west marine, they said 'try automotive'
didn't find it at autozone, but i did find thick black butyl tape, which i had a heck of a time finding earlier.
 

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Try your local glass shops. It took a few months and visits to alot of glass shops before I was able to locate a acceptible gasket. RV dealers usually have the butyl tape in stock (white, grey)
 

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Meat Popsicle
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Discussion Starter · #16 ·
Went to the glass shop and they said i always had the power, all i had to do was click my slippers together.

They said the gasket i brought in wasn't that bad, a heat gun would soften it up, it's not supposed to be water tight anyway. They sold me a tube of silicone for five bucks, i asked if it was ammonia or acid based and he glazed over. Glass shop pun, lol.

So I made a horrible mess of the first window and then established these conclusions:

1. Butyl tape is for between the frame and the fiberglass. Not on the glass, not around the top and bottom of the frame.
2. The gasket's purpose is to provide the pressure to keep the window and the silicone friendly.
3. From the start, I should have masked off the window, the outside of the frame, the rubber mallet, the gel coat, everywhere but the mating surfaces. heh heh mating.

Getting out windows that have been caulked on with 4200 (unnecessarily, i suspect, when they were also screwed on), I learned:
1. Two flathead screwdrivers, masking tape everywhere.
2. Pound flatheads in, make a tiny crack and work it larger.
3. Utility knife in the crack, cut the best i can.
4. PUUUUUUUUUUUUSH

All this stuff is written down elsewhere, but I'm one of those skeptical smart arses who has to learn everything himself.

Them acrylic windows look real good. Stuff like this gives me respect for their simplicity.

One last thing, I'm thinking about running a bead of 4200 around the perimeter of the rim, strictly to protect the butyl. Is this stupid?
 

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One last thing, I'm thinking about running a bead of 4200 around the perimeter of the rim, strictly to protect the butyl. Is this stupid?

Yes.
 

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I'd also point out that you can buy Debond, which is designed to soften the grip of polyurethane sealants, like 5200 and 4200 and makes it a lot easier to remove stuff bedded with them.
 
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