Wow, you could not have picked better timing to post this. Two weeks ago bought a 1981 42 (mine's hull #176) with the same exact issue. I'm compiling my materials right now to remove then fill and fiberglass the poorly replaced windows. In mine, it looks like they removed the original windows and placed plywood in its place and painted them black and put some black caulk around the seems. Plywood, no fiberglass. So the wood naturally rotted through and anytime it rains or we take a wave over the bow, we get a puddle of water on the salon entertainment center area. Is that plywood that you used to fill? it almost looks like Coosa. What did you find when you removed the old stuff? what size material did you use? If you have anymore pictures...post them all! My thought was to buy the thinnest marine grade ply i could find, then put a layer of CSM on them and layer them until i reached flush with the gel coat. then a layer of 1708, fair and sand then paint. I see you are also de-browing. Thats also my plan. Don't be shy with the pictures, i'd love to see what i'm getting into before i start tearing things apart. Good Luck, and let me know any lessons learned you have and i'll do the same as i plan to tackle this in the next couple of weeks.
Looks just like mine did. When I pulled the plexi and teak frame out it was pretty easy Cleaned everything up, the inside is framed with fiberglass so no rot Used Honeycombed plastic core and cut and beveled to fit then glassed and gel coated the inside white. Now glassing in the out side and when it's finished gel coat that too. The color will not match but I'm not concerned too much because I plan on repainting the whole boat in the next year. Mine is 181 Please post pictures of yours
That is a huge relief to hear that the frames are glassed in and not just open wood. i was concerned i'd open it up and find a much larger problem than just replacing two windows with wood and fiberglass. I'll post some pictures of my boat in a new thread. don't want to hijack yours. Looks like we have a lot of the same projects ahead of us though. my rubrail also needs replacing...