DIY window frame replacements

alk

alk

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Has anyone attempted to fabricate their own replacement window frams, hopefully with sliding windows?

One of the boats I'm looking at is a vintage ( old, in bad shape, and really cheap) Pacemaker Flybridge. Like most Pacemakers of this era, the windows in the salon leak profusely, resulting in the need for a new interior. Assuming I buy this boat, before I replace the interior wood, I will need to fix the windows. I've seen quotes for custom made aluminum frames, with sliding windows - but the cost I've seen on the forums, about $3,500 is more than I would be paying for the boat. Can this be done as a DIY project, constructing frames out of aluminum, wood, epoxy, etc? I'd like to be able to open the windows, but that isn't a set requirement. Any ideas?

thanks.
 
You might try a local glass shop. Don't tell them it's a boat and it will be cheaper.
 
The window frame itself isn't that big of a deal; and you can buy window channel (tracks) from Boatfix.
I've used the Beckson "channelmate" http://www.beckson.com/channel.html and have been happy with it. I glued mine in place with 5200 (there might be a better way). Tolerances are close though so be careful.

Boatfix sells both the Beckson product and a similar product by Stanpro
 
If you're talking rectangular channels, it shouldn't be to bad.

Suggest you go to www.crlaurence.com. look under glass hardware and then track assemblies.

Bob
 
interesting. So if I'm replacing the side salon windows in a sedan type interior, do the openings have to be square, or does the glass just have to be cut to match the openings? Right now they are not squared, but I assume I could use wood and then glass over to get them square.

Any chance you have pictures of the job you did?
 
I have wondered why you just cant use vinyl windows from Home Depot. They are custom made to any size. The tempered glass is the same as used by boat makers and the vinyl frames wont corrode.
 
I dont see why not except for the mention of rollers. I would not want anything made of metal involved. Surely they will be better than the old sliding glass in a wood frame so common on old trawlers.
 
the only other consideration will be any structural support for the fly bridge provided by the old windows. I dont think the vinyl will serve that function but that should be easy to replicate.
 
None of the off the shelf vinyl windows have tempered glass, unless you get into patio door sized units. You can special order units with either tempered or laminated glass. Plus, the vinyl window manufacturers are using thinner extrusions today. They are using aluminum or steel re-enforcements for strength purposes.

Photos of the application would be helpful. They would give us a better idea of exactly what you're dealing with.

Bob
 
There are a lot of manufacturers like www.motionwindows.com who produce speciality windows that you could use.

Bob
 
those look like good windows but when I change my windows I would really prefer to avoid aluminum in favor of vinyl.
 
Here's a couple picture of the boat I'm looking at, sisterships obviously.

Judging by the interior, it seems every interior window, probably 12 of them, have leakage issues. The ones I'm most concerned with are the 'sliders' in the salon, port and starborad side. I think I can seal the fixed ones. As mentioned, I know I can get nice looking custom fit replacements from several vendors, but the boat is somewhat of a junker, and I don't want to put $3,500 of replecement windows in a boat that I hope to buy for half that amount. These boats are pretty much all windows, which is the problem, all that weight of the flybridge has nothing to support it - which is why I was considering glassing off part of the openings - to allow for a standard sized window, and to add some support for the 'second floor'.

http://www.pacemakerboatowners.org/topic.asp?TOPIC_ID=1563

http://farm4.static.flickr.com/3167/2745844756_3a904e9436_o.jpg
 
I looked at the links you provided and have a better idea as to what your dealing with regarding the windows. Can't tell by the photos what the window frames for the sliders are made from or what their rough dimensions are.

If you want the sliders to operate, like they do now, and the frames are wood, you can either seal the existing frames and update the weatherstripping with new wool pile or bulb seal. Secondly, you can fabricate a frame out of aluminum and weather strips. That should not be too hard, looking at the configuration.

If you don't care if the windows operate, you can either fabricate a one or two piece window with a center mullion or one piece. A glass shop can cut you a piece of lami (1/4" or 3/8") should be satisfactory. That will be better than tempered, for this application. You better check the safety codes (I'm not familiar with the requirement based upon window placement). Secondly, you can replace the existing glass with a one piece unit an seal it into the frame with butyl and polyurethane.

Bob
 
They can be rebuilt to original for a reasonable price. A friend whose hobby is woodworking has done it several times, usually on older boats. He says the key is to keep the weep holes open.
 
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