Repairing the Windows

I fabricated a piece of new mahogany to replace a rotted section (top right of the picture). Because this will be painted, I can use Fill It to blend the pieces seamlessly. I used a lot of 3M 5200 behind the wood and the exterior fibreglass, which had pulled off the hull. There was quite a bit of water damage so I soaked everything in CPES. I clamped everything together overnight to let it set up.















I put on the respirator and slathered on the Fill It.















With the new window frames in place, this is starting to look like progress.

At the bottom of the picture is a rotted piece of frame from the port v-berth window. I used some spare mahogany that came with the boat to fabricate a replacement piece (directly above). At the top of the picture is another rotted frame that I've repaired with Smith's Fill It epoxy. All pieces will be coated in CPES before they are remounted. This is obviously a common place for water to get inside the boat, especially if it is left neglected, as I suspect this boat was.
















The new port window frame in place. I filled the seam with Fill It epoxy.

Making this cut was difficult, for me at least. Because it's a 60 degree angle I couldn't do it on the table saw, so I constructed a kind of mitre box. This is the one cut that will show when the frames are mounted.

I used the spruce templates to make the finished window frames out of 1/2 inch ribbon stripe Meranti marine plywood from Noah's Marine in Toronto. It isn't an exact match to the original Luann for colour, but the grain is close. I've bleached it down a bit. Here I've laid the surviving piece on top to match the placement of the screw holes.