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Bob, this past Spring I removed all my laminate pilot house windows,
replacing them with thermopane, tempered outside, laminated inside, total of
an inch thick, including the spacer bar.
I had a few conversations with glass installers and the Sika corporation
about the right caulk. I have teak exterior frames which hold the glass in.
They recommended an automotive window caulk (#250 or 251, can't precisely
remember the number). This is a thicker caulk than 291, by contrast, sets up
quickly. I liked working with it. The consistency of crunchy peanut butter
as it begins to set, easily molded and trimmed. If you want to do some
trimming, do it as soon as it sets...two weeks later, it's rock hard. The
Sika people strongly recommended I also use a mineral glass activator, "Sika
Activator," to be applied about 20 minutes before the caulk. They claim that
nearly any caulk will eventually separate from mineral glass without the
bonding created by the Activator. My can of Activator came from Sika-Canada,
since I was at a Vancouver shipyard. I think it cost around $40 for 450 ml.
I of course also used their teak primer, which I realize won't be necessary
in your case.
I was a little suspicious of the need for the Activator, but just a couple of
days ago, happened to be inside a Ketchikan autobody shop which also does
automotive window glass installation. Ketchikan gets 144+ inches of rain a
year, so these guys probably know a thing or two about stopping leaks. I
inquired about their process...they use a two part caulk, heated, brand name
I can't remember. They abhor any form of silicone. I asked about whether
they use any sort of "activator?" "Absolutely," was the response. "You have
to use it on glass." Well, okay. A thought...since you're working with
metal, it might be of value to visit a car windshield shop.
Good luck to you. My job also entailed routing out nine existing interior
teak frames. The toughest part of the job was getting the glass fabricator
to satisfactorily duplicate the angles of my windows. Of all the projects
I've gotten involved in on the boat, this was the granddaddy. Love the new
thermopanes, though...free from scratches, quieter, warmer.
Vic Kucera
Pacific Star
Krogen 42-53
Ketchikan, AK
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