Cabin Windows and Deck Hatch Installed

The windows and the fore-deck hatch are installed.  Yay!  It was a lot of prep-work for the new cabin windows but like anything you spend extra attention to the end result is good.  I couldn't be happier with how they turned out.  It pretty much took us most of the weekend to install them.  The weather cooperated down to the minute.  The temperature outside was about 50 degrees right on the borderline for what is acceptable for Sikaflex.  After dry fitting the windows I masked both the windows and the hull allowing for a small cap bead of adhesive.  Jilann and myself tag teamed the installation while Sally watched Emily.  We used #8 countersunk screws that are hex driven so the look would be closer to a rivet for the finished look.  On the interior I used fender washers to spread out the clamping load with a low profile nylocks.  A small space heater helped boost the interior temperature aiding in curing.

After we bonded in the windows it started to rain lightly.  Just in the nick of time.  We will let the windows cure for a day and then the forward hatch will be installed.

 The below pictures are a day later and the masking is ready for removal.

Jilann removing the protective covering.  This is the best part.

The tint of the windows is perfect and matches the tint of the forward deck hatch.  The fore-deck patch is not finished yet but pretty close.  The long process of fairing it smooth.  The plan is installing Raptor decking.

Now all major holes in the deck have been filled.  I have aluminum tape over all exposed holes and I used some vacuum bagging material and butyl tape to seal the electrical pass through for the mast electrical.  If anybody out there needs window templates for a Ross 780 let me know I will hook you up.

The process was long creating something from nothing:
(Paper templates, traced cutouts, digitized with a faro arm, manipulated in the computer, 1:1 templates, transferred holes to templates, templates to Clearcut Plastics, they made router trim fixture, parts made, and added c'sinks, get parts two weeks later, dry fit, mark boat, scribe paper backing, remove windows, Exact-o knife out paper backing perimeter, mask boat, prime the bonding surface of the window with fifty dollar primer, wait thirty minutes, apply Sikaflex to boat in a pyramid shape to ensure no air bubbles upon squeeze out, position window and align holes, add fasteners, squeeze out material, make mess, get some on clothes, add tiny cap bead, clean up mess, watch adhesive dry, sit on heating pad)

Removing the masking was the best part and the windows and forward deck hatch look great.  The forward cutout I believe was designed for a Bowmar hatch but I found a Lewmar hatch that will work great from Fisheries Supply.  Thanks again Paul.  I do like the quality of the Lewmar hatch and the features as well.  I will take some pictures after the adhesive dries.  The good thing now is the boat is getting sealed up and I can run a small space heater in the inside of the boat.  I will also sleep better knowing that I am not dependent on some flimsy tarps.  A week ago we had 50 mph winds and the tarps were getting worked.

Now on to the main companion way hatch.  I have to reinforce the hatch with a little epoxy and some fiberglass fairing compound and gel-coat.  I am gearing up for the interior improvements as well and I have found a good source for the marine Plywood, thank you Simon.

Spring time will be here before we know it and we will be ready to sail.  For now we are ready for the winter and the race against the weather is over.