2005 Explorer 275 Bait Tank Window Reseal

[MV2]

My 2005 Explorer 275 bait tank was leaking. I am resealing the window, but could use some advice. Has anyone had experience with this mid ship bait tank? I am new to doing this type of stuff.

The window is sealed about 1-2” all around and is recessed slightly, probably to create smooth inside for no harm to bait. Looks like there was a layer of seal over some kind of gasket or another material?  It is not adhering underneath to the edge as I can lift it. (photo)

Should I remove it all and start over or just replace the areas that are obviously disintegrated (bottom) and reseal all again?  What should I use?

On a side note, I think this was the last year of these boats?  This particular boat was fully loaded, with air conditioning, hot water, Kohler 5E Genset which has since rusted through the bottom of the cooling system. Probably can’t afford to replace the Genset so may try a rebuild. Slowly finding the problems and rebuilding. The bait tank window leak turned into another big one. I will post the pictures of the Genset project too if any interest.

[RickK]

You can buy (I did) a sheet of rubber that you can make gaskets out of. You can get them in many thickness and width. I realize that the pressure is outbound from inside the baitwell and the body must be smooth so the bait doesn't bump their nose. You can use the rubber to get close to the level and a caulk it smooth out the edge?

[MV2]

Got it, thank you.
Clean all old material.  Seal the gasket to the inside of the tank, then seal the window to the gasket.  What do I use for that which will last?

[RickK]

Looking at the old material, can you salvage it and add to it?

[MV2]

Good suggestion, I will have to definitely replace the bottom strip. And then I will have to reseal the edges as they are loose. There is also some cracking of the glass I need to address just under the finger in the photo of the seal.

[MV2]

I removed a portion of the bottom of the seal, and it looks like it is all just a 3/8” or so layer of sealer material.  You can see where it has failed in the bottom.

I am assuming it is 4200?  Does that seem appropriate?  It is certainly flexible, but very tough.

I will remove it all and start over. Just want to make sure the 4200 will stick to both glass and plexi?

[MV2]

I guess my question is, should I use 4200 or 5200 sealant to seal a plexiglass window to the fiberglass bait tank?  I think 5200, as it has lasted for 25 years last time and was hard to take off, so it must have been 5200? It’s going to take a lot to build up like the old seal.

[RickK]

You may have to buy a small tube of both and do tests of both, to both materials.  I think they take 7 days to set.

[MV2]

Thanks Rick, really appreciate your help in these trying times.

Got the old seal off the rest of the insert area. Looks like I should also clean out the gap, and reseal that too.

Next project is to clean the plexiglass window. Can I buff out all the scratches?

[MV2]

The plexi window has a roughed up area where I think the sealer needs to adhere.

Looks like it was also scored for measuring the opening.

[MV2]

Finally got to this project. After testing per Rick’s suggestion, the material was consistent with 5200 after it cured for 4 days.

I went ahead and sealed it but got some bubbles. Oh well, it should still last 10 years or so!