PROJECT SHEET NO. REPLACEMENT OF WINDOWS: Project from John Cordial, M101 CORDELIA OF IONA Materials & Tools: Perspex 3/8" Putty Knife Sealaflex Mastic & Cartridge Gun Spanner Solvent for Mastic Shorthead Screwdriver White Spirit (for cleaning) Masking Tape, 1" wide Protective gloves & clothing Electric Drill Procedure: 1 Remove all nuts and washers from inside the cabin. 2 Commencing at the bow position of window, start removing the bolts 3 carefully, by unscrewing them one at a time. Place the putty knife between. the perspex and the fibreglass gelcoat of the cabin side the free the perspex from the old beading seal. (NB - I found that the old perspex window will snap vertical of centre when the final portions of bolts are removed; the reason for this must be that the tension on the perspex, which is released, causes the ateriey ‘to flex and break from top to bottom in a striaght line, near enough). DO NOT DISCARD THE WINDOW WHICH YOU HAVE JUST REMOVED BECAUSE THIS IS THE PATTERN FOR YOUR REPLACEMENT WINDOW. 4 5 10 Fix masking tape to the underside of the old window to keep it rigid for processing to the new window. Fix masking tape to one side only of the old window over the bolt holes in vertical strips and over the leading edge, with a 2" surplus to hold new window in place to pattern for cutting to shape. Turn the new window and pattern over (one unit taped together). With a pin, pierce the masking tape on the surface of the old window until you’ find the old bolt holes; then apply the bit which you propose to use to drill into the new window (I suggest this is done all around the window). Using a small fine bit (to avoid material fracture within the perspex) Tau etecric driM, and with the drill set AT DEAD SLOW ~ drill from the old window through to the new window. Next fit the correct bit and KEEPING THE SETTING SPEED AT DEAD SLOW, drill as before. Remove all masking tape. Place masking tape from inside the cabin, half width against the cabin lining with the other half exposed. (This will prevent the Sealaflex fron messing up the lining inside the cabin). Apply white spirit to remove and clean all old sealant and dirt. Apply a generous thickness of Sealaflex to the cabin window base area. Position the new window and insert your bolts in into the previously drilled holes. From inside the cabin, place the washers and nuts onto the bolts, starting from the top bow positions of the window and proceed alternately from top of window to bottom. THE NUTS SHOULD BE HAND TIGHT ONLY AT THIS STAGE. Leave for at least 24 hours ~ then tighten nuts one or two turns, Do not overtighten as this will cause_the perspex to fracture.