Originally Posted by mamos
Thanks for the replies
Chris, I am based in the UK so it is probably not an option. Also, I do not want to replace the windows with glass as we do not want this to happen again.
Thanks Andy. Is Lexan UV stable. I am also thinking of doing away with the rubber seal so I can fit thicker plastic.
I will bed the plastic in some sort of sealer
Is this a good or bad idea. Keeping the rubber would mean I could only 2mm maybe 3mm lexan. This just seems too thin but I am open to ideas
You cannot get a thicker plastic into the metal frame that would make any difference.
The Lexan material, is the "bullet proof" plastic, depending on it's thickness.
You can beat on Lexan with a hammer and not break it. You may put a dent in it, and that's about it.
If you wish to eliminate the gasket, that's OK, but use "Vulkem" sealer within the metal sash. DO NOT use any form of "silicone sealer".
Be cautioned, that the 2 pieces of aluminum framing (sash) are held together with some small rivets, and, a steel plate. You will find corrosion around that plate which can cause great difficulty putting the two halves of the sash back together.
You will also need some small rivets, that I suggest you obtain "before" you start your project. Those small rivets hold the two sashes together, as well as the hinge reinstallation.
Lastly, make super sure that you do not bend, in any way, the hinge. If you do, you more than likely will not be able to reinstall the window.
Good luck with the task.
Please make a post after completion and let others know how you did.