So after installing the windows the small screws I used for retaining the windows were a bit too long. I measured the length extending into the cabin and decided to buy some new shorter screws rather than cutting off the threaded portion. I was worried about the heat that would be transferred from the screw body to the Acrylic. So I picked up the shortened screws and backed out all of the screws retaining the windows I knew the Sikaflex was sufficient at retaining the slightly bent windows. The reason I'm posting this is to share what I learned on this process. With the screws backed out I painted the interior under the fender washers with the new interior paint and then this is where I made my mistake. I took some Sikaflex and loaded up a syringe. I then injected a drop of sealant into the root of the countersunk window so all of the screws would be sealed. What happened next is the formation of a micro crack adjacent to the countersunk hole in the areas of high stress. Ugh! It is like pulling a gummy worm tight and licking it. A lot of cracks appear out of nowhere. Luckily it was not that bad.
Two micro-cracks radiating from the countersink.
Not everything has been successful or perfect but that's ok. I have learned a lot so far and I know this project is not going to be perfect. I can always replace a window if required and the second time around I could do it in half the time the fortunate thing is the micro crack is tiny and I drilled a small hole at the end of the crack to stop the spread. Luckily this only happened to about 6 of the 100 c'sinks. No worries.
The thing I'm learning about this project is it is important to jump in and aggressively attack the project. Sitting by idle and waiting for all of the details to be figured out will result in the boat sitting on the trailer. I look forward to working on more projects this weekend.
Blizzard with Emily Rainbow!
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