Dehler 41DS Windows

[Petef]

The windows on the Port side of my Dehler 41 DS are really badly crazed and starboard side are starting to go. I got a quote from Hamble Yacht Services which was around £1320 for the parts and £4900 labour to both sides!!! I guess they are telling me they don't want the job

Has anyone here had any experience of changing boat windows on a Dehler 41 DS? or any other boat and have some tips because it looks like I'm going to have to do the work.

[MSB]

We have similar issues - leaks mainly. Take a look at http://www.syfuga.co.uk and you will see a 'contact' hyperlink. The gentleman who owns Fuga (John) had his windows replaced.
Also (a very 1990s web site though) have you seen the following? http://hadlo-43547-001.dsvr.co.uk/Pages ... ction.html I have been told by a friend that this company proved to be most helpful when he replaced his windows.

There are different Sika compounds and primers required as you probably know already.

Anyway - an initial guide for acrylic windows (PDF) will download if you click the following

http://www.google.co.uk/url?sa=t&rct=j& ... YtqemJBMzA

Maybe this is of some use. We will have a go at our windows when the weather is favourable.

Post back with news.

All the best.

[Fordehler]

I got Dehler 41 DS yard nr. 46 and has recently replased the windows, due to cracs in the polylaminate and ekstensive leaks.

Since the material is quit cheap, but the windiws are curved so we had to make a mould, I ordered 2 sets of windows.
One set is offered to the marked for about 1500 euro+ transport from Norway.

The job is simple to do, but the main problem with my boat was that the yard has cut out to much from the hull, and there is not enough support underneeth the aluminium framing. I had to make new and better support by using epoxy resin as putty and that way creating better support for the gasket material. I used butyl rubber, since most sikaflex,Tec -7 and similars do not addhere well to the plastic in the windows.

Paal Hegen-Jacobsen
pjac@statoil.com

[Petef]

Firstly apologies for not getting back sooner, and secondly many thanks for your replies. The Window replacement still hasn't taken place due to a) being a fair distance from the boat, b) whe we do go down if the weather is good we go out . Also 2014 we cruised to France, and the Channel Islands for a while, and 2015 we sailed to the West Coast, Scilly Isles, Down the West Coast of France calling at most of the French Islands as Far as Ile De Re, Then back up the mainland Ports starting from La Rochelle, calling in at La Roche Bernard, Around Brittany to Guernsey, Cherbourg and back to the Solent. However, now I need to do the work, so thank you for your input.

[waljoh]

I see my name mentioned above, so thought I would add a comment.

We suffered from leaks, and also crazing. In 2010, in Turkey, we decided to replace the windows. Working in conjunction with a local supplier of acrylic (mainly for e.g. display stands) introduced by the marina, we removed the windows in groups of 3. Most of them almost fell out. The supplier took the originals away, and brought back precisely cut and drilled copies. Meanwhile we removed all traces of the previous sealant, and cleaned up the seating, finally making sure that it was scoured with wet and dry. We then masked up around the windows inside the boat, and also outside. The new window was offered up, and masking applied to the inside, leaving the mating surface exposed. The mating surface was then also lightly scoured with wet and dry (including the edges).

It is essential to obtain and use the correct Sikaflex UV-resistant primer. This is painted onto the boat, and importantly, onto the window. It is black, and forms a good bond. Following this, sealant is applied, the windows inserted and screwed home, but with small rubber spacers made from the old sealant to make sure that not all sealant is squeezed out. The windows will accomodate the bending necessary to seat properly. The sealant is then laid off with a wet blade, and when dry the masking is removed. Job done.

Result: No leaks whatsoever over 7 years, but the new acrylic is already crazing. Maybe a quality issue with the acrylic, that only cost around 600 euros, including cutting and drilling. We used 14 tubes of sikaflex, and two bottles of primer.

My opinion is that in the original build they did not properly remove the releasing agent, and scour the surface, prior to fitting the windows. The primer is expensive, ($40 per bottle I seem to think), and may not have been used.

Creeping crack cure made the leaks worse, by softening the sealant.

[Petef]

In September 2017, finally bit the bullet and replaced the windows on our Dehler 41 DS. I was unsure at first how to remove the old windows. I removed all the nuts and bolts from the Port side (which were the worst damaged. Only to find that the windows were still in place and not moving at all! Realised that the windows were pressed against the frames by rubber strips Doh!. Replaced all the nuts and bolts using Sabatack 750XL sealant (this got a better write up in tests by a sailing Mag. than Sikaflex) in the holes. Removing the strips was quite easy but we were careful not to damage them whilst easing them out. It was then a job of removing the previous sealant and pressing the windows out of the frames from outside. The windows were taken to a nearby Acrylic company that used the old windows as templates for the new ones. We couldn't get the same shade of grey as the original (anywhere in 8mm Acrylic) so settled for a slightly lighter shade. Which was actually a bonus as it made the boat a lot lighter inside. It took a week to get the windows cut, in the meantime we sealed the windows with strong plastic (black rubble bags) and duct tape. Cleaned the inside of the frames with Acetone. When the new windows were received the edges were cleaned (again with acetone) Then a 10mm x 2.5mm bead of Butyl Tape (from Reddiseal https://www.reddiseals.com/product/butyl-tape-sealant) very carefully, it is very very sticky stuff! When the outside edge of a window was done, the backing paper was started and the window offered up to the frame. Here you have to be really careful to align the window (as a second attempt will mean you will need to use new butyl tape! When you are happy with the placement (it took two of us one inside and one outside) pull the the backing paper off the tape whilst the person inside gently presses the window against the frame. When finished the window is water tight! (I know because it started to rain during fitting). I then went inside and pressed the windows against the butyl strip to ensure there were no air pockets, but don't be too hard as the butyl will thin out. I then sealed around the frame and window were the original sealant had been with the Saba sealent, then replaced the original rubber strips (this was the hardest part, getting the rubber strips back in place) which press the acrylic against the butyl, the butyl remains flexible and sticky and therefore creates a great seal for a marine window. We have had no problems with the windows to date, and we have since been across the channel and come through the Alderney race with 27 Knots of wind plus (forecast was for 20-22 knots) with a large swell and waves breaking over the boat as we came through from Dilette to Cherburg. Now I've done this I would hesitate to do it again It took a few hours and about £600 in Acrylic and sealants, a bit different from the cost quoted originally

[Petef]

Our circumstances have changed and we have now decided to sell our lovely Dehler 41 DS. Please see www.dehler41ds.com