window rings

[Florin {VACATIONER}]

What materials did you guys use for the window rings?

Thanks

Florin

[Dave R1]

I used 3/8" luaun plywood because I had lots of scrap since the deck, cabin roof and hatches are made of it. I had made a template to guide a router for cutting the openings in the cabin sides so I used the template to make a pattern for the outside and a guide bushing for the inside of the ring.

They are epoxied and screwed from the inside.

[Florin {VACATIONER}]

Thanks for the tip. So you have the piece of plexy or lexan sandwiched between the rings and cabin wall and they are epoxied together? Or did you leave provisions to remove one of the rings at a later date so that you can change the window pane if or when it becomes damaged or scratched badly?

Thanks

Florin

[Dave R1]

Yes. Howzat?

I used Plexiglas for the windows becuase I couldn't get Lexan soon enough to meet the launch date. The plex just fits the opening. the rings overlap the opening by about 3/4" all around. The outer ring is epoxied in place. Then I installed the window and screwed another ring to the inside. (actually IIR, the inside rings might be 1/4" plywood) I got some self adhesive foam weather stripping and ran that around the edge on the outside face of the plex before installing the windows. Since the side is 1/4" plywood, there's a fair amount of compression.

Due to time constraints, I ended up letting the hardware store where I got the Plexiglas cut the pieces for me. I made a template of 1/4" plywood for them to work from.

If I were to do the whole process again, I would have started with a template for the outside edge of the ring first and worked from there to get the inside of the ring and the opening in the cabin side. Still, I like the idea of making the template and using it to cut the openings in the cabin. It made quick work of the job, all the port windows are identical and the "glass" pieces are interchangeable.

g'luck

[Florin {VACATIONER}]

Thanks Dave, I got it now. I have all the ports cut out in the cabinside already. I used 3/4" ply to make my rings out of.... Trouble is that I used the first one as template and made the others just like it with the router. Unfortunately the template had some voids in the center laminations of the ply and the router followed the contour and the voids. They don't look too badly, but they're not perfect and I'm thinking of making new ones. I should have made the template out of mdf or masonite board. I'm also considering cutting rabbets in the inside ones so that the window pane fits right in and you cannot see the edge at all.

I was thinking of maybe installing the window pane between the outer ring and cabin so that the cabin wall edge is not exposed to the elements.

Whad'ya think?

Florin

[Dave R1]

3/4" ply? Wow. That seems kind of thick to me. I suppose if you rabbet the back of it for the plexiglass it would work. My cabin sides aren't flat enough so the rings have a slight bend to them. It was easily handled by the 3/8" ply and clamps.

I do like your idea about covering the edges of the plywood on the cabin side. I put epoxy on mine and kept addiing it until I got a nice coat. Some spots seemed to soak up more epoxy than others

I expect it will be fine. Will you post pictures of your progress?

[Russ Sylvester]

My originals were plywood but they only lasted about 2 seasons before delaminating very badly. My new ones are made from 1x doug fir stock that has been cut out and planed down to about 3/8". One other thing I learned from the first set is DO NOT use 5200 to bed the rings. It will be near impossible to get them back off later on. Use 4200 and life will be much better.

[Florin {VACATIONER}]

Since I hear fir checks quite badly in about a season or two unless it's covered in glass, and now we know that ply will eventually delam, now I am thinking maybe it's safer to make them out of oak or some other wood that will survive at least five years in the elements if varnished properly.

What d'ya think?

thanks

Florin

[capt jake]

My rings are WRC on the inside with a rabit to inset into the cabin side slightly (to accomidate the lexan window).

The outer rings were made from an 'old' heavy bronze door kickplate and through bolted through the Cedar.

Sealant was 3M 4200, as it is plyable and can be removed. It is also very easy to apply and clean up using and adhesive remover (I used West Marine's remover as they recommended it).

[tdrown]

I would paint the backsides of the rings, part of them is visable. This is first thing I will be doing as soon as I remove them.

[Florin {VACATIONER}]

Yes, painting will be done for sure on the back side as well.

Thanks

Florin