Why 'Reseat' the Saloon windows?
Over the past 12 months, we noticed small black flakes appearing around the saloon windows. After investigating, we traced the issue to the black acrylic bonding primer used to improve adhesion between the acrylic panes and the saloon structure.
It appeared the original acrylic panes were not lightly scuffed before the specialised primer was applied. As the windows were exposed to years of heat and UV radiation, adhesion gradually deteriorated. This allowed the primer to separate from the acrylic surface, resulting in the black flakes we observed.
The new adhesion process.
An inspection confirmed that five of the six saloon windows required reseating, which was not unexpected given they are the yacht's largest window panels (both forward-facing opening hatches) were also leaking and showed significant corrosion. Small water stain run marks were visible on the inside and outside of the forward windows, confirming long-term water ingress.
One of the Leopard's best design features is its forward access door, which provides excellent natural ventilation throughout the saloon. With this in mind, we chose to replace the forward window panels with new fixed acrylic panels. The cost was comparable to replacing the two heavily corroded hatches, while eliminating two common leak points and reducing future maintenance. We discuss the quality, common issues and long-term reliability of Lewmar Portlight Flush Mitre hatches in this separate article.
The old black acrylic bonding primer was carefully removed from each pane before the surfaces were thoroughly cleaned. Areas requiring primer were then masked off and lightly sanded with 220-grit abrasive to promote adhesion. A specialised black acrylic bonding primer was applied and allowed to cure in accordance with the manufacturer's recommendations.
The windows were then resealed and bonded using Sikaflex® 295 UV, with the large window panels requiring a substantial volume of adhesive to achieve the correct bond line and sealing performance.
Once installed, each pane was carefully braced and left undisturbed for seven days to allow the adhesive to fully cure. The supports were then removed and the final edge finishing completed. Despite the scale and complexity of the project, the work was completed with excellent attention to detail and a high standard of workmanship.
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The project was undertaken by Snick As, who managed the installation professionally despite challenging conditions that included high humidity and frequent rain. Allowing the bracing to remain in place for the full curing period ensured a high-quality result. Credit goes to Steve and his team for an excellent outcome.
