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with aluminium framed windows
As a minimum we would replace the four fixed windows all facing forward, which were the worst affected - two in the main saloon and two in the forward berth. At the same time we would convert the two in the forward berth to opening windows. This would give us much better through ventilation of the galley. It had got very stuffy in the heat of the 2003 summer.
We roughly measured all the windows to sufficient accuracy for quotation. We did all the windows to get an idea of the total cost. This information was recorded on a diagram showing the windows shape and key dimensions. We divided the windows into groups that would look OK if they were the only ones done. The overall aesthetics were important. We could decide later whether to do all windows or just some.
The diagrams were duly handed over to the major marine window suppliers at the Jan 2004 boat show and quotations followed a few weeks later. There was not much to choose between the prices but Houdini were quicker off the mark than their opposition and had been more helpful at the show - so they got the order: for the four windows.
The next trick was to make a paper template for each window sufficiently accurate to ensure that the finished window would fit into the aperture. Erring on the safe side for a guaranteed easy fit could mean that the windows would be too small to hide the paint line between the existing rubber and the recently repainted superstructure. Too large and there would be lots of swearing followed by a lot of unnecessary filing and grinding!
What's the big deal you may ask - well we didn't want to take out the existing windows until the new ones were ready.
A small piece of rubber extrusion was carefully cut away from the top of one window at the join and where the weather couldn’t get in. This would tell us exactly what the cross section of the rubber was, as well as the thickness of the superstructure plus interior finish (glued to the inside of the steelwork ) which turned out to be 8mm. Using a feeler, sample measurements were taken of the rubber overlap on the steel superstructure, around each window to confirm consistency.
A paper pattern of the inside surface of the exposed glass was made, in situ. This was transferred to a drawing and then enlarged by the relevant dimension taken from the rubber cross section measured from the sample - to show the calculated size of the aperture.
The finished templates were dispatched to Houdini. They then drew up manufacturing drawings for our approval. We took these drawings down to Starry Night and offered them up to each window in turn. All seemed OK, but we did notice that all window corners had been adjusted to the standard manufacturing radii. It looked as if Stevens might have used the same radii when they had cut the apertures in the superstructure 19 years ago! Harmonisation of European standards or coincidence?!
We gave our approval to Houdini for manufacture, and about ten weeks later we had our windows: with enough bubble-wrap to start our own packaging company!
The type of window we had chosen clamps onto the superstructure by means of an inner frame, which is screwed to the main window frame with self-tappers. The window is sealed to the superstructure with a self adhesive tape. Sounds simple - no drilling involved.
The big day came, point of no return - we would remove an existing window and try our hand at fitting a new one. The old glazing rubber was held in place by a retaining filler strip, which came out very easily. But the old rubber had lost its flexibility and wouldn't bend enough to let the glass come out. A sharp knife quickly cut away the retaining lip on the outer glass side. The large rubber sucker procured for the purpose made it easy to lift the glass out. The rest of the rubber followed. We were committed! So far so good.
The edges of the aperture were cleaned up, and the moment of truth had arrived - would the new window fit – yes! Well almost! Some relatively light filing (about 15 minutes worth), mainly in one corner, and we were there.
The raw edge of steel was primed, the sealing tape applied to the window and the window inserted into the aperture. Fitting the retaining frame inside was easy. The self-tapping screws were progressively tightened until the frame was home. A plastic extrusion was inserted into the frame to hide the screw heads. Finally a bead of transparent sealant was applied round the outside edge of the frame - belt and braces. One down and three to go.
Each window took less than an hour to fit for the whole process including removal of the old window. Some filing was needed for all of them, but no where near as much as we had feared. We did the whole job in half a day having expected to take a day to do just two.
A year later including some serious waves over the forward berth windows and we can report all is well. No leaks, and the windows look good.
Cabin windows as at Summer 2003
Window glazing rubber showing silver
retaining filler strip
Our first aluminium frame window in place
The old paint clearly visible where it had been
covered by the rubber - the new windows only
just hide this
Inside view showing the clamping frame.
The black plastic extrusion hides the
screw heads.
The finished job - Summer 2004