Adventure 208 window repair and modification

MooseheadDoc

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Location
Moosehead Lake, ME
Model
Adventure
I have followed several threads on repair of leaking or damaged windows on cuddys (cuddies?).

I will be attempting my own version, gradually over time.

My scenario:
- ‘93 Adventure 208
- leaking port side Cuddy window
- prior owner(s) have already caulked the &$@“& out IC every seam, channel, and crevice. The windows and screen are still present, but nothing moves
- the head liner is minimally damaged and is salvageable
- the interior window trim is gone, leaving exposed screw tips

I sat in the boat during a heavy rain the other day. The current leak is small. The source is probably unknowable.

My thoughts:
- I am not interested in removing and rebedding the entire window casing
- the source of the leak between casing and hull, aluminum window channels, screw holes, or other
- I don’t need an OEM repair, but I don’t want bubble gum and duct tape.
- I use the boat in Northern Maine. I don’t need the window to open. The deck hatch and starboard window are adequate.

So I’m thinking i will try:

- remove the black exterior channel molding (intact, but pulling away in places).
- clean out prior sealants from channel.
- one at a time remove each screw and replace with bolt/washer/nut and bedding compound. This will eliminate the exposed interior screw tips, and hopefully eliminate screw holes as a leak source.
- replace and bed the gasket if possible, seal the channel with a black sealant if not.
- remove existing windows and screen, clean channels of old caulking
- replace window with single piece of plexiglass (type and thickness TBD). Bed thus in outermost channel and seal.
- from inside, peel back headliner, clean away exposed caulk/bedding compound, reseal, replace headliner.
- make new interior trim (TBD. Will need to cover nuts from earlier step.

Thoughts or suggestions?

A few pics of “before “....
 

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