Just letting you know...

I ain't dead, and neither is the project. I just had a few other things in life to take care off, and today is way too miserable to do sanding. :)

Bonsoir

Bravo for the surgery. Be carefull for the recovery.

Amicalement

Eric

Annie has explained this several times. Her method is taken from the Gudgeon Brother’s manual on West epoxy. It goes something like this.

• 1.      Start with dry-fitting the item with wooden screws.
• 2.      Mark the position of the item carefully.
• 3.      Remove the item and drill up the screw holes to about double diameter.
• 4.      Fill the holes thoroughly with epoxy. If the surface is vertical, I would first brush epoxy resin thoroughly in the holes and then squeeze in thickened epoxy afterwards
• 5.      Put the item back into position and drill holes for the screws again. Actually, Gudgeon Brothers recommend using machine screws as wooden screws, that is without using nuts (if the plywood/wood is thick enough).

Anyway, this prevents water from entering the endgrain of the ply.

In hot and humid conditions, it appears to be the only alternative.
Personally I would remove the two screws on one window on Redwing 2 after a couple of weeks of hardening the glue. Then I would just seal the screw holes with epoxy. If the window doesn’t come loose during the next two weeks, I would do the same to the rest of the windows.

No guarantees...

Arne

Looks nice, Gary.

I would keep a close eye on the windows. Rotten cabin sides on my Pelorus testify that plastic screwed to the outside face of a gently curving ply cabin side, with small thru-bolts at about 12" centres, can fail even when bedded on mastic. It is possible the builder simply did not do a good job, although it did look OK about seven years ago. If there is any sign of water getting into one of them, say in a few years time, you can always rip it off and re-do it I guess. Rain water and humid climate is plywood's worst enemy, but I guess it's just a matter of keeping an eye on things. (Lovely looking sail, I might add).

Just a little update. I've now reached the point where I am putting paint,  as opposed to stripping it off. I'm getting close to flipping the boat to tackle the hull.