Best way to remove window from mahogany coachroof + new sealant

[phantomracer]

I need to remove the 1/2" thick plexiglass window from the coachroof to do a repair on a crack in the wood.

The window is bedded in Boatlife sealant in a mortise in the wood, with a custom stainless trim cover. I think the cover should come off pretty easy. It is the removal of the plexiglass that concerns me. I really don't want to damage the inside of the boat... or damage the plexiglass!

Is mechanical removal (pick, knife, etc) the best way? Should I bother with any adhesive removers like boatlife release?

Also, when reinstalling the plexiglass, what would be the best practice? Should I use boatlife again? or use butyl tape instead.

[Cheechako]

Boatlife shouldn't be too high strength bonded like some sealants. It stays flexible IIRC? I would remove the trim ring and work my way around the Plexi with a flexible very thin blade of some sort. Once the bond starts failing as you do this, it should come right off with a little encouragement.

[Tupaia]

Make an opening through the sealant and insert a strong fishing line or steel leader attach a Tee handle at each end to form a cheese wire then with a friend one end work your way gently around the lens. Patience and care will yield a damage free if somewhat time consuming result.

[bil56]

after sticking tape on the plexi to protect, use an oscillating multi-tool, interior/exterior, it should cut the sealant ...

[phantomracer]

Originally Posted by Cheechako

Boatlife shouldn't be too high strength bonded like some sealants. It stays flexible IIRC? I would remove the trim ring and work my way around the Plexi with a flexible very thin blade of some sort. Once the bond starts failing as you do this, it should come right off with a little encouragement.

That was, more or less, be the plan of attack. I haven't removed the trim yet but boatlife usually doesn't get rock hard.

I am suspecting mechanical removal is going to be the way to go.

[phantomracer]

Originally Posted by Tupaia

Make an opening through the sealant and insert a strong fishing line or steel leader attach a Tee handle at each end to form a cheese wire then with a friend one end work your way gently around the lens. Patience and care will yield a damage free if somewhat time consuming result.

where the window is sitting in a mortice/recess, any line from the outside in would be in the shape of a Z, so probably won't be overly effective without damage to the wood.

[phantomracer]

Any thoughts on best practice to bed the glass back in, after the repair?

I have used (and have plenty) Bed-it Butyl tape. I have not used it on wood, however. I am leaning toward using it, unless there is a better choice