Forward cabin window leaks and problem solving

[Despacio]

You may have followed my saga of leaks, or maybe you have your own story.

My forward cabin windows leaked, so the plywood under the fiberglass delaminated and became thinker, which moved the metal lip of the windows (fastened on the inside only) inside the fiberglass, leaving a hole for more water to get inside.

What I found after tearing it all out is that it was a screw holding the eye brow infront of a window that was doing the leaking. The screw had been too short and pulled out probably the day it was installed, leaving an open hole for the water to pour down after being directed that way by the eyebrow. You could plainly see the extra sealant someone used at the time filling the gap caused by the lack of a screw.

I also found that the holes for the windows was over cut, almost to the outside of the trim ring.

I replaced the too short screw, removed everything from the inside, glassed up the holes where the windows used to be, bonded new 1/2 inch plywood to the inside surface and recut the windows. They are so tight now that they won't leak with no sealant. I did use a bead of 4200 around the frame of the window and the outside surface.

I then replaced all of the old paneling in the forepeak. Luan covered in white formica. Looks great, but what a lot of work.

Interestingly I found an MCC trawler about the size of mine at a dealer for sale. It has the exact same name as mine had, and the same home port. I did a little research, it had the same owner at the same address.

I now realize the guy cut his losses and after spending a lot of money and effort, gave up and replaced the boat with a very similar one that didn't have the leaks this one had.

I now see him as the ultimate problem solver, because all of his efforts and expense didn't fix any of the problems.

You could see where a lot of effort was put into the leaking forward cabin windows for example, but they never figured out it was the screw above the window.

Just like the leaks in the aft cabin was the screws that went through the radius of the deck and into the teak decks. I didn't find that out until I removed the decks.