sounds like this has been pretty well covered but FWIW, I've used primarily brownelles acra-glass gel. I've done it in the "Sitka method" as well as just filling the hole and redrilling (acraglass will drill and screw and shave pretty easily within the window before it gets really hard (in my basement, say 15-24 hours later).

Last edited by UtahLefty; 08/08/07. Reason: typo