Cal 34 Salon Windows - Glass our Plastic

Hello all, I am looking to replace the 4 original salon windows on my 1978 cal34 MKIII. In talking with Mark at Mark's Plastics, he suggested glass instead of plastic inserts as they hold up much better. (downside, if you do serious offshore sailing and they break out, this is not good - plastic is better in this case) My current windows (and cabin sides)have a signficant curve by design. Placing a straight edge in the middle of the window, there is a quarter inch gap between the straight edge and window outside edges. With the new glass being flat, I don't see how glass inserts can work. Mark mentioned that he has placed glass in other Cal34s and someone on the Cal34 yahoo group mentioned they replaced with glass in their Cal34 MKI. Any thoughts from folks? Very curious. I don't see how glass will fit well. Does the Cal34 MKIII have a different exterior design than earlier models? Thanks, Stefan

Tap Plastics has acrylic (Generic Lexan) which is reasonably priced and is stronger less brittle and lighter. I have removed glass ports in Cal boats and replaced the glass with lexan. Happy 4 July!!! MY BEST, Mike From: Bay Sailor <st… [at] hofmeyer.org> To: Ca… [at] yahoogroups.com Sent: Fri, July 2, 2010 12:30:41 PM Subject: [Cal_Boats] Cal 34 Salon Windows - Glass our Plastic Hello all, I am looking to replace the 4 original salon windows on my 1978 cal34 MKIII. In talking with Mark at Mark's Plastics, he suggested glass instead of plastic inserts as they hold up much better. (downside, if you do serious offshore sailing and they break out, this is not good - plastic is better in this case) My current windows (and cabin sides)have a signficant curve by design. Placing a straight edge in the middle of the window, there is a quarter inch gap between the straight edge and window outside edges. With the new glass being flat, I don't see how glass inserts can work. Mark mentioned that he has placed glass in other Cal34s and someone on the Cal34 yahoo group mentioned they replaced with glass in their Cal34 MKI. Any thoughts from folks? Very curious. I don't see how glass will fit well. Does the Cal34 MKIII have a different exterior design than earlier models? Thanks, Stefan ------------------------------------ Yahoo! Groups Links http://docs.yahoo.com/info/terms/

I used 1/4 inch Chemcast GP Acrylic Sheet from Tap Plastics. Double tape the old window to a rough cut new one and use a router with a bearing to duplicate exactly the old one. The bit is called a flush trim bit. I bolted my router to a piece of wood with a hole for the bit to make a temporary router table. Worked great. Here is a picture of the windows. http://l-36.com/display_pic.php?pic_name=mast_step/windows.jpg&pic_title=Windows Here is a video on using a flush trim bit http://www.youtube.com/watch?v=zTIWwOoMda4 <http://l-36.com/mast_step/windows.jpg>Allen On Sat, Jul 3, 2010 at 8:50 AM, mike farrell <ve… [at] yahoo.com> wrote: > > > Tap Plastics has acrylic (Generic Lexan) which is reasonably priced > and is stronger less brittle and lighter. I have removed glass ports in Cal > boats and replaced the glass with lexan. > Happy 4 July!!! MY BEST, Mike > ------------------------------ > *From:* Bay Sailor <st… [at] hofmeyer.org> > > *To:* Ca… [at] yahoogroups.com > *Sent:* Fri, July 2, 2010 12:30:41 PM > *Subject:* [Cal_Boats] Cal 34 Salon Windows - Glass our Plastic > > Hello all, > > I am looking to replace the 4 original salon windows on my 1978 cal34 > MKIII. In talking with Mark at Mark's Plastics, he suggested glass instead > of plastic inserts as they hold up much better. (downside, if you do > serious offshore sailing and they break out, this is not good - plastic is > better in this case) > > My current windows (and cabin sides)have a signficant curve by design. > Placing a straight edge in the middle of the window, there is a quarter inch > gap between the straight edge and window outside edges. With the new glass > being flat, I don't see how glass inserts can work. Mark mentioned that he > has placed glass in other Cal34s and someone on the Cal34 yahoo group > mentioned they replaced with glass in their Cal34 MKI. > > Any thoughts from folks? Very curious. I don't see how glass will fit > well. Does the Cal34 MKIII have a different exterior design than earlier > models? > > Thanks, > Stefan > > > > > > ------------------------------------ > > Yahoo! Groups Links > > > > >

Interesting video Allen. Im going to test this method as from reading up on it folks who have tried it report it works very well especially in heavy sea way. This method will be used on the four salon portlights. Building both interior trim and storm cover plates for rough weather is simplified as you have an inner edge to work with. 1/4 inch lexan is available from several sources including ebay selection of lexan type being very important. ref: http://www.thecoastalpassage.com/windows.html If you read the methodology there is room for change on the application of silicones and I would use MR-10. So a bit different, but the concept is the same. What I was looking for is a reliable solution that can withstand high temp fluctuations and getting beat up in a heavy storm, not that I want to be there, but the potential remains. Even tied to a dock in the winter, such covers could have been useful...as they also serve to keep the heat in and reduce condensation by providing and air break. Your needs may be different. The forward ports, in the head, one per side, both Beckson's will get this treatment, as its removable and simple. Again a variation will be adapted. http://www.rogerlongboats.com/09Portlights.htm The final piece of kit that the 3-29 needs is a proper sea hood and sliding hatch cover. The hatch cover is the greatest annoyance as there is a 1/4 inch gap around the forward edge and runners. Probably will have to build new hatch boards as well with this project in order to get it somewhat tightened up. Interestingly enough the old cape dory's 25 came with a very well designed and integrated sea hood, sliding cover and boards. Interesting on such a small boat. Best regards /ch

Damn Good Advice, Listen to him! MF From: Allen Edwards <al… [at] PaloAltoPhoto.com> To: Ca… [at] yahoogroups.com Sent: Sat, July 3, 2010 9:09:19 AM Subject: Re: [Cal_Boats] Cal 34 Salon Windows - Glass our Plastic I used 1/4 inch Chemcast GP Acrylic Sheet from Tap Plastics. Double tape the old window to a rough cut new one and use a router with a bearing to duplicate exactly the old one. The bit is called a flush trim bit. I bolted my router to a piece of wood with a hole for the bit to make a temporary router table. Worked great. Here is a picture of the windows. http://l-36.com/display_pic.php?pic_name=mast_step/windows.jpg&pic_title=Windows Here is a video on using a flush trim bit http://www.youtube.com/watch?v=zTIWwOoMda4 Allen On Sat, Jul 3, 2010 at 8:50 AM, mike farrell <ve… [at] yahoo.com> wrote: > Tap Plastics has acrylic (Generic Lexan) which is reasonably priced and is >stronger less brittle and lighter. I have removed glass ports in Cal boats and >replaced the glass with lexan. > Happy 4 July!!! MY BEST, Mike > > From: Bay Sailor <st… [at] hofmeyer.org> > >To: Ca… [at] yahoogroups.com >Sent: Fri, July 2, 2010 12:30:41 PM >Subject: [Cal_Boats] Cal 34 Salon Windows - Glass our Plastic > >Hello all, > >I am looking to replace the 4 original salon windows on my 1978 cal34 MKIII. In >talking with Mark at Mark's Plastics, he suggested glass instead of plastic >inserts as they hold up much better. (downside, if you do serious offshore >sailing and they break out, this is not good - plastic is better in this case) > >My current windows (and cabin sides)have a signficant curve by design. Placing a >straight edge in the middle of the window, there is a quarter inch gap between >the straight edge and window outside edges. With the new glass being flat, I >don't see how glass inserts can work. Mark mentioned that he has placed glass >in other Cal34s and someone on the Cal34 yahoo group mentioned they replaced >with glass in their Cal34 MKI. > >Any thoughts from folks? Very curious. I don't see how glass will fit well. >Does the Cal34 MKIII have a different exterior design than earlier models? > >Thanks, >Stefan > > > > > >------------------------------------ > >Yahoo! Groups Links > > > >

I should have added what I used for caulk and cleanup. My situation is different in that I needed something that would stick to acrylic and wood. There is only one thing on the market that will do that: LifeSeal. And there is only one solvent that will dissolve caulk and not acrylic and that is turpentine. I would not be surprised if LifeSeal was the best product for your boat as well. Pure silicon does not hold up very well in a marine environment. Allen On Sat, Jul 3, 2010 at 9:41 AM, chris123 <ch… [at] gmail.com>wrote: > > > Interesting video Allen. > > Im going to test this method as from reading up on it folks who have tried > it report it works very well especially in heavy sea way. This method will > be used on the four salon portlights. Building both interior trim and storm > cover plates for rough weather is simplified as you have an inner edge to > work with. 1/4 inch lexan is available from several sources including ebay > selection of lexan type being very important. > > ref: http://www.thecoastalpassage.com/windows.html > > If you read the methodology there is room for change on the application of > silicones and I would use MR-10. So a bit different, but the concept is the > same. What I was looking for is a reliable solution that can withstand high > temp fluctuations and getting beat up in a heavy storm, not that I want to > be there, but the potential remains. Even tied to a dock in the winter, such > covers could have been useful...as they also serve to keep the heat in and > reduce condensation by providing and air break. > > Your needs may be different. > > The forward ports, in the head, one per side, both Beckson's will get this > treatment, as its removable and simple. Again a variation will be adapted. > > http://www.rogerlongboats.com/09Portlights.htm > > The final piece of kit that the 3-29 needs is a proper sea hood and sliding > hatch cover. The hatch cover is the greatest annoyance as there is a 1/4 > inch gap around the forward edge and runners. Probably will have to build > new hatch boards as well with this project in order to get it somewhat > tightened up. Interestingly enough the old cape dory's 25 came with a very > well designed and integrated sea hood, sliding cover and boards. Interesting > on such a small boat. > > Best regards > > /ch > > > >

mike farrell wrote: > > Tap Plastics has acrylic (Generic Lexan) Not to be too picky, but I thought that Lexan was a trade name for polycarbonate, and Plexiglas was the trade name for acrylic. It matters some, because the different plastics tolerate different sealants, as I recall (can't remember which plastic dislikes which sealant. I used the wrong one when I replaced a glass port glazing with Lexan but have seen no evil consequences yet.) Chris Campbell

Not just the sealants, Chris, but the sun/UV resistance. I forget which one crazes more. "Still crazing after all these years..." Cheers Charlie From: Ca… [at] yahoogroups.com [mailto:Ca… [at] yahoogroups.com] On Behalf Of Chris Campbell Sent: Tuesday, July 06, 2010 2:02 PM To: Ca… [at] yahoogroups.com Subject: Re: [Cal_Boats] Cal 34 Salon Windows - Glass our Plastic mike farrell wrote: Tap Plastics has acrylic (Generic Lexan) Not to be too picky, but I thought that Lexan was a trade name for polycarbonate, and Plexiglas was the trade name for acrylic. It matters some, because the different plastics tolerate different sealants, as I recall (can't remember which plastic dislikes which sealant. I used the wrong one when I replaced a glass port glazing with Lexan but have seen no evil consequences yet.) Chris Campbell

Thanks for the trail on this. Actually, still have a question... Mark's Plastics created the original production plastic window frames and can make the frames to spec. Since my frames are original plastic, they are brittle and it is time refresh. Mark suggested I use tempered glass for my MKIII within the frame. However, My MKIII frame and window have a curvature and I can't see how flat tempered glass would work. I have heard the Cal 34 MKI can handle "flat glass" and was wondering if that is a design change between MKI to MKIII. Anyone put Tempered glass in Cal34 MKIII salon windows? It would be great to hear your results. Cheers, Stefan --- In Ca… [at] yahoogroups.com, "Husar, Charlie [USA]" <husar_charlie@...> wrote: > > Not just the sealants, Chris, but the sun/UV resistance. I forget which one crazes more. > > "Still crazing after all these years..." > > Cheers > Charlie > > ________________________________ > From: Ca… [at] yahoogroups.com [mailto:Ca… [at] yahoogroups.com] On Behalf Of Chris Campbell > Sent: Tuesday, July 06, 2010 2:02 PM > To: Ca… [at] yahoogroups.com > Subject: Re: [Cal_Boats] Cal 34 Salon Windows - Glass our Plastic > > > > mike farrell wrote: > > Tap Plastics has acrylic (Generic Lexan) > > Not to be too picky, but I thought that Lexan was a trade name for polycarbonate, and Plexiglas was the trade name for acrylic. > > It matters some, because the different plastics tolerate different sealants, as I recall (can't remember which plastic dislikes which sealant. I used the wrong one when I replaced a glass port glazing with Lexan but have seen no evil consequences yet.) > > Chris Campbell >

Stefan, I know the 40s and 36s have tempered glass. Mike Holiday > To: Ca… [at] yahoogroups.com > From: st… [at] hofmeyer.org > Date: Tue, 6 Jul 2010 18:59:41 +0000 > Subject: [Cal_Boats] Re: Cal 34 Salon Windows - Glass or Plastic > > Thanks for the trail on this. > > Actually, still have a question... > > Mark's Plastics created the original production plastic window frames and can make the frames to spec. Since my frames are original plastic, they are brittle and it is time refresh. > > Mark suggested I use tempered glass for my MKIII within the frame. However, My MKIII frame and window have a curvature and I can't see how flat tempered glass would work. I have heard the Cal 34 MKI can handle "flat glass" and was wondering if that is a design change between MKI to MKIII. > > Anyone put Tempered glass in Cal34 MKIII salon windows? It would be great to hear your results. > > Cheers, > Stefan > > > > > --- In Ca… [at] yahoogroups.com, "Husar, Charlie [USA]" <husar_charlie@...> wrote: > > > > Not just the sealants, Chris, but the sun/UV resistance. I forget which one crazes more. > > > > "Still crazing after all these years..." > > > > Cheers > > Charlie > > > > ________________________________ > > From: Ca… [at] yahoogroups.com [mailto:Ca… [at] yahoogroups.com] On Behalf Of Chris Campbell > > Sent: Tuesday, July 06, 2010 2:02 PM > > To: Ca… [at] yahoogroups.com > > Subject: Re: [Cal_Boats] Cal 34 Salon Windows - Glass our Plastic > > > > > > > > mike farrell wrote: > > > > Tap Plastics has acrylic (Generic Lexan) > > > > Not to be too picky, but I thought that Lexan was a trade name for polycarbonate, and Plexiglas was the trade name for acrylic. > > > > It matters some, because the different plastics tolerate different sealants, as I recall (can't remember which plastic dislikes which sealant. I used the wrong one when I replaced a glass port glazing with Lexan but have seen no evil consequences yet.) > > > > Chris Campbell > > > > > > > ------------------------------------ > > Yahoo! Groups Links > > > Hotmail has tools for the New Busy. Search, chat and e-mail from your inbox. http://www.windowslive.com/campaign/thenewbusy?ocid=PID28326::T:WLMTAGL:ON:WL:en-US:WM_HMP:042010_1

Whatever! It looks good and does not leak. I took the recommendation from the Tap Guy. My Best, Mike From: Chris Campbell <cl… [at] charterinternet.com> To: Ca… [at] yahoogroups.com Sent: Tue, July 6, 2010 11:01:42 AM Subject: Re: [Cal_Boats] Cal 34 Salon Windows - Glass our Plastic mike farrell wrote: > Tap Plastics has acrylic (Generic Lexan) > Not to be too picky, but I thought that Lexan was a trade name for polycarbonate, and Plexiglas was the trade name for acrylic. It matters some, because the different plastics tolerate different sealants, as I recall (can't remember which plastic dislikes which sealant. I used the wrong one when I replaced a glass port glazing with Lexan but have seen no evil consequences yet.) Chris Campbell