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Hi Jim. I haven't gotten ready for the windows yet but a couple of
thoughts.....
Could you cover the entire surface, both sides, with masking tape.
Carefully cut off the area where the Sikaflex will be in contact around the
perimeter. Put in the windows and "finger off" the stuff that sploogies out
while it's still fresh. After it sets up remove the masking tape. The area next
to the Sikaflex gasket will be super thin because you wiped most of it off. It
will just peel off along with the tape.
You can get sticky material from the plastics store. I would try a sample
of anything on a small scrap piece of plexi first. It doesn't have to be the
exact plexi you're using. just any good quality piece of scrap. This too can be
had from the plastics store.
Would it be possible to "inject" the sikaflex into the gap ? I was worried
about getting the space equal all around and eliminating air bubbles.
If I could put some little spacers in there to maintain the disk in
the center, clamp it in place, and then seal off the gap leaving small
"injection points" around the edge. Now make small injection nozzles from scrap
sheet metal, like little funnels. Connect these to tubes and a manifold
with the Sikaflex being pumped into the manifold, through the tubes and
injection nozzles, and into the gap. This would drive out the air as the space
is filled.
Keep pumping until all the bubbles are pushed out and a big "bead" is
showing on the outside. After it sets up just "knife" the bead off and install
the retainer ring with a pre-cut EPDM gasket.
It sounds complicated but maybe not that much. I've made the little
nozzles before and although not pretty, they worked well in eliminating bubbles
when injecting sealers like silicone etc. The spacing of the injection nozzles
is critical. Enough so the Sikaflex or whatever sealer flows in
there evenly and leaves no bubbles behind.
Frank D.
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