Cal Windows

The original windows on the Cal 46 in the raised salon area were heavily crazed, darkly tinted, an small, allowing little light in and very limited views out. Two of the three windows on the starboard side were also badly damaged (along with part of the cabin top and trunk. The solution became replacing the old windows with new and larger pieces of bronze tinted 1/2" lexan.

Original Windows

The originals were removed one at a time, the hole's elarged, the new sheets of lexan fitted, holes drilled for 1/4" bolts (we thru bolted with finish washers outside and nylock nuts inside instead of using the self tapping screws previously employed). The windows were bedded in a thick layer of white 3M 101, applied liberally to ensure a well sealed gasket. There was squish out everywhere when the bolts were tightened, proving there was enough sealant. When installing we removed the outer proctive film layer, and cut the inner film around the cutout. This way the layer where the window sealed to the cabin trunk could be removed, but the inner portion left on until after installing the window to protect it from the 101 squish out.

Much greater view from inside!

Some of the structural fiberglass was removed from the cabin trunk in the process of enlarging the windows. However, 1/2" Lexan is also extremely strong (actually pretty much bullet proof, most bullets or sea debris will at best only crack, not penetrating all the way through, upon direct impact). When bolted on at approximatly 4" centers with 1/4" stainless bolts to properly join the lexan and fiberglass the structural elements of the cabin should in no way be comprimised.

I'll post more pictures of all the new windows installed when I can find them on my computer. The new windows make the boat much brighter and friendlier inside. It no longer feels like walking from the cockpit into a dark dank hole. The cabin is now also a far more comfortable place to sit out of the weather and view the scenery when on anchor.