Aluminium windows?

[Andy G]

I have ventured down this path previously. The wooden windows are fast coming to the end of their life. Over the last 18 years we have filled sanded, painted at various intervals. I think some of the windows now have more filler than wood.

What to do? I tried making a new frame, which was moderatly successful, though not to shipwright standard. I thought perhaps I should take a crash course in marine window frame 101, maybe change the frames to pre made aluminium units. I don't like the idea of aluminium windows on the old girl, but they certinally do have advantages.

Not sure what to do, I wondered if any IG owners have ventured down this path and how did it turn out.

Keen for ideas and advice.

Cheers,

Andy

 

[BruceK]

Andy, I had tired aluminium windows replaced on the Masters 34 I owned before the IG, a former CYCA committee boat. It was done by shipwrights at Brooklyn who cut a cardboard template, sent to a mfr in Queensland, probably on Gold Coast. You could search for a manufacturer, I think there were several. Too long ago to recall $, but price was surprisingly reasonable. There are lots of options, color, sliding or not, or part sliding part not, tinted or not, etc. I was happy with the result. The important thing is correct manufacture to size, which became the shipwright`s responsibility, especially as manufacturer was distant. The windows were freighted to the shipwright packed in wooden frames, and fitted by them. IMO, it`s worth doing.

 

[Andy G]

Thanks for that Bruce. I have already sent a preliminary enquiry to a marine window company in Queensland. I will wait on their reply.

 

[Pascall]

I don't know if there is a supplier in the USA but this company makes ship windows in composite.
Different colours are available, possibly they can even be painted.
The advantage of composit window profiles is the insulating effect compared to aluminium.

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www.topwindows.nl

 

[Andy G]

I'm not sure that a supplier in the US would be of help as I am in Sydney, the other side of the Pacific Ocean(assuming someone hasn't renamed it!).

The product does look very good, I will make some enquiries to see if any over here is doing anything similar.

 

[psneeld]

I just used RV (Caravan down under?) camp together windows.

Couldn't save the glass as most broke getting the old windows out, so I wasn't saving anything with going with whole new windows. They held up pretty well for 11 years.

If I had all the glass, maybe DIY or local fabrication might be the ticket.

 

[Datenight]

In the early 2000’s I used Aluminum 2000 out of Lancaster, Pennsylvania. The company has changed hands since then so may be under a different name if still in business. They were very reasonable and easy to work with. I sent templates and drove down from Connecticut to pick them up when done. Matched the frames to the Awlgriped cabin with their powder coat paint.

Rob

 

[Bacchus]

In the early 2000’s I used Aluminum 2000 out of Lancaster, Pennsylvania. The company has changed hands since then so may be under a different name if still in business. They were very reasonable and easy to work with. I sent templates and drove down from Connecticut to pick them up when done. Matched the frames to the Awlgriped cabin with their powder coat paint.

Rob

Al 2000 is now a division of Pompanette.

https://pompanette.com/companies/aluminum-2000/

 

[Datenight]

Thanks Don.

 

[mvweebles]

@Andy G - are you trying to replace the entire window or just the outside trim bezel? When I had my windows redone, the forward fixed windows were trimmed in fiberglass which should be easier to work with than wood. My side opening were plastic frames with an inner "clamp" ring that sandwiches the cabin wall between the clamp ring and the window assembly. Just so happens that the company that made windows and ports for Willard from the 1970s was still business so I had them make the side windows. While aluminum is stronger, I'd go with plastic from a reputable manufacturer as aluminum corodes over time.

Peter

 

[Andy G]

I had thought of replacing the whole unit as the original windows appear to be intergrated. However, I will take a close look this weekend to see if it may be possible to leave the interior wood surrounds in place and remove the outer surrounds and glass and replace.

Thanks for the idea.

 

[Brisyboy]

Hi Andy,
Ditto your problem for us on Malagari, esp the six fwd windows in the forward cabins. In the end I removed them all - from the outside - the frame is (for us anyway) faired into the sides and the frame itself is screwed onto the outer sheet of the foam sandwich...so first find all the screws - (plugged of course with teak) then I cut behind the frame with a multi tool and the frame came off - eventually. This will leave you with an aluminium section that the glass slides in inside the wooden frame. I got these out by destroying the old wooden frame.

Here we differ - I replaced them with wood - local timber yard made some profiles for me (out of iron bark - geeze that stuff is hard!!!!)

The only challenge for alum sliders here is the cabin side is slightly curved so the frames will need to be packed out.

Luckily the frames in the saloon are fine however removal would be the same. Good news here is that the saloon sides are flat so aluminium frames would pop straight on.

 

[Brisyboy]

PS, all done from the outside, no inside frames were touched in this process. I did have to remove a section of square beading that was covering the middle of the foam sandwich - but with a the judicious use of some epoxy filler they dont really need to be replaced

 

[BruceK]

From unreliable memory.Andy`s boat did not have foam deck coring; so probably not in the cabin sides either. Be good to retain the interior timber frames though.

 

[Andy G]

Yes, George your description of the process rings a bell. Iron Bark frames, well nothing on earth will rot them in your lifetime.Your description of removing the outside frames is what I did about 8-9 years ago on the stb forward window. Lots of packing required as I remember. My effort was OK, def not up to professional standard though.

Bruce, I think on further reflection I would like to retain the original wood lining for the interior.

I do like the process described in Pascall's post. Though I have not come across anything comparable in Oz. Surley there must be a business opportunity for an enterprising young shipwright to do something similar. Build up a reputation replacing old leaky trawler boat windows. God knows there are enough of them.