Cabintop structure and repair around side windows

[ilaria]

Hi! I need some help to understand how my boat was built and how to fix some water damage around the windows.

I have a Jeanneau Sun Kiss 47 from 1988. When I bought it a few months ago, I noticed that there were signs of water leakage through the side windows. One window in particular was in such a bad shape that the wood on the inside had rotten. So I first removed the windows and let things dry for a few days and then I started working with hammer and chisel to remove the deteriorated wood. I was expecting to find some sort of sandwich construction, but I was surprised when, after removing about 7 mm of plywood, I found a greyish rock-like material connecting the top and the side panels of the cabin. This material is hard but tends to crumble when hit with a chisel and it looks as if it was either spread with a spatula or squished inside the gap with a gun or similar equipment.

My question now is twofold: is the cabintop structurally held together only by this very uneven hardened glue, without any fiberglass? And how do I go about fixing it? Should I simply cut a piece of plywood and glue it in the hole with some epoxy?

A big thanks to anyone who might shed some light on this!

[Charlie-Bravo]

Hi, many alterations and repairs may have occurred in the last 34 years, boats of this era often have to be repaired for window leaks.
Your repairs may well exceed the construction of the original as you have access to much better adhesives and seals, and lets face it, not many spares of original parts .... window trim etc, are likely to be in existence.
Non of this need spoil your enjoyment of the boat , once the main repairs get finished, it becomes a test of human endurance and ingenuity, and as you are not scared to attack with the chisel would appear to be the sort of new owner this boat needs! congratulations on your purchase.

The links to your pictures do not seem to work, and a few pictures might generate a few ideas once we can all see them.

Good luck
CB

[MartyB]

If you have access to Facebook. Go to sun dream 28, I believe Arcadia site too. Both have pictures and some posts from folks redoing what you have done. I have YET to do this with my 85 Arcadia.

The basic thing most have done, remove plywood, the gray epoxy? Filler glue used. Remove plastic/lexon? outer window. Clean smooth down to just fiberglass. Replace with new material, ie plywood and window plastic.

My window appears to be glued into place with a black sika flex. Not sure if a UV rated version was available then. I would use the Sika Flex, 3M 4000 or 4200, or Pettit has a UV rated equal out in last year or so. These "caulks" are what is available to me in US. Get what you have available that is equal where you live.

Inside I would use one of the previous mentioned caulking type sealants, bolt everything together as installed initially.

I'm sure one could also replace with actual round brass or equal windows too..... possibly more, or less work....

Not recalling van article in the hints and tips area of main page here...

Good luck with project.

Marty