Help! Our windows hate us!
I have a flat nose 2001 International Amtran. We knew that there would be issues but the windows have been kicking our butts.
We started by taking all the windows out, cleaning off the old seal and then washing the windows.
Then we replaced the windows with 3M dynatron 550 and new weather foam strip across the top. We made sure to go thicker in the bottom corners because of the gaps.
However, we noticed that it wasn't drying, at all. So we removed that and decided to turn to butyl tape.
We used butyl tape the exact way that we saw in some videos on YouTube, on the base on the windows and up the sides of the windows. But we did double up on the sides because we noticed that there was a huge gap between the window and the frame. The double up closed the gap but we still had an issue.
The butyl tape was very noticeable from the outside and our windows stuck when we opened them. We then went to every window and tried to remove the visible butyl tape. Unfortunately, it leaked when we tested it.
So we decided to start again.
This time we used a mixture of butyl tape and sikaflex 221. We did the same thing with the butyl tape but this time we put a bead of sikaflex on the sides of the frame as well. When the window were in, we went outside and smoothed the sikaflex. Even though they were VERY well covered, they were still leaking when we tested them.
So we decided to go a path we didn't want to go, silicone. We also decided to weld the corners of the windows to close the huge gaps we saw. Then we watched another video, followed their technique exactly, only putting in 6 windows. And once it was cured, a big rain came. Three out of six were leaking.
We honestly couldn't understand how the water was getting in, so we just stopped working on the windows for a while and moved on to other projects.
Now we are back to the windows, but it's not getting any better.
This time we tried a foam weather strip across the top, rubber weather strip down the sides, butyl tape across the bottom, sikaflex on the outside, and Great Stuff foam on the outside corners. We thought, this is it, we did it!
We only did four windows like this. Three of the windows are leaking. Two of the windows are leaking from an area we can't find, and all three of them have leaks coming from the seal that holds the glass in.
Please help! We don't want to keep throwing money at these windows if nothing we do will work! We are posting a lot of stuff on Instagram (PolyPhoenixFamily, if you want to see what we've done so far) about it, but if you need pictures or anything just let me know.