Sail Boat Marine Windshield DIY Project...

Sail boat marine windshield was one of the last things we were worried about.



It took a long time researching on the internet companies that could do this for us. Finally coming to the conclusion this was going to be another project we would take on ourselves.

The front windows on the pilothouse are stationary (fixed) windows.

1/2" acrylic plastic (optical grade) acrylic plastic is harder to scratch or yellow then other plastics used for windows.

There is a common theme you will find on this website and that is we use templates (patterns) all the time to help get angles and sizes right.

Use large pieces of scrap wood, large flat (old refrigerator, stove) boxes...you get the picture.

They are easy to get if you go to your local home improvement center, ask them for it. Shipments of wood come with throw away pieces. Our aluminum sheets were separated with thin pieces of wood.

We used them for templates also.

Lay the piece of cardboard up to the window and trace around the opening of the window. The windows in boats are so irregular this will help you out a lot getting the sizes and shapes right.

Cut your new pattern out...

Lay your pattern down on the acrylic plastic, trace around the outside. Use a marker, so you can see the outline easily.

A skill saw will cut the acrylic with no trouble. Use a plastic cutting blade.

You will have some plastic burrs on the edges of the plastic, they are easily removed with a metal file. You want to get the burrs off so you have a tight fit in the window opening. Plus a water tight fit!

Sail Boat Marine Windshield Interior

Check your work and place your newly made window into the opening. Check to make sure all the burrs are gone and it is laying flush (flat) against the window jam.

Clean the window area with lacquer thinner of any grease, finger prints, dirt etc.,

Next butal rubber wind shield sealer is applied around inside of frame. Leave no spaces...put a foam rubber gasket in place.

Place your window down on these.

On the outside we placed 1-1/2" aluminum frame around the outside of the windows. Painted them black as you can see pictured above.

Use stainless steel machine fasteners.

Sail boat marine windshield, The best advice I can give you is take your time. Creating templates will save you a lot of time and less stress.

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