Replacing Main Cabin Windows in W31s and Centaurs etc

Supplies

Barrel Screws/Interscrews 3.5 x 10mm increasingly difficult to find

Window Seal Rubber:- Square U Channel Type US 158 from here Seals Direct

Everything:- Eagle Boat Windows

NOTE - The window rubber seal from mid 1970's onwards boats can be a different size to US 158 - It has a bevelled edge and is 12mm wide. Check before you buy - it can be an expensive mistake!

Method.

Warning this is messy with a capital M! and is best done on a large flat surface covered with newspaper.

It's best to replace all the barrel screws (also called Interscrews) which hold the windows to the cabin structure. This is a two handed job and needs good screwdrivers to avoid rounding the screwheads. The interior screws screw into the outside screws, hence the name Barrel Screws or Interscrews.

Having removed the windows and cleaned up all the windows and window frames etc., prepare them all with a final clean of meths or appropriate cleaner and allow to dry. It is best to start with the aft window as it has parallel sides and hence easier to do for the first time.

Start with the bottom aluminium frame and rubber seal. Cut the rubber seal to size and run a thin bead of sealant in the bottom channel of the rubber seal. Position the seal so that the join will be midway along the top edge of the glass. DO NOT run the bead of sealant all way along the seal, but just enough to extend past the limits of the bottom aluminium frame ends. Now run another bead of black sealant inside the channel of the bottom aluminium frame along its whole length. Insert the window and seal into the bottom aluminium frame gently hitting the top edge of the glass with the heel of your hand. This will bed it down nicely. As you're seating it all into the aluminium frame check carefully that the seal isn't twisting as it goes in. You'll need some sort of blunt pushing tool to correct any twisting. If you do run the bead of sealant all the way round the full length of the rubber seal you'll find that the sealant oozes out of the top edge and covers your hands with black goo! Now repeat the process with the upper frame. You'll find that the rubber seal “grows” and will need trimming.

The forward windows are done similarly but needs an extra push using a soft faced mallet to seat the angled portion into the bottom aluminium frame. Fairly obviously this must be done first before applying the top frame.

Lastly screw in the aluminium tags which lock the two frame halves together.

Cleaning up. Fairy Liquid used neat acts as a good barrier to black sealant. Clean up using white spirit, propriety sealant cleaner, soap and water.