Ron passionately and patiently replaced the windows of his sailing yacht with polycarbonate. The new windows not only allow more light in, but also offer a much clearer view. After 25 years, it was truly time to replace the old, cloudy windows. Thanks to polycarbonate, Ron now enjoys strong and durable windows.
The Project
Ron replaced the cloudy plastic windows on his Southerly 115 sailing yacht with 10 mm thick clear polycarbonate panes. The task started by removing the old panes, which was quite a challenge due to the tough rubber seal. Ron describes how he carefully worked with a chisel and sharp knife to remove them. He measured the old panes and used a jigsaw to cut the new polycarbonate sheets to size. The new panes were then primed and placed in the sanded and cleaned rebate. He also had to slightly bend the panes to fit them.
Step-by-step guide
steps
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Remove
Remove the old pane and write down the dimensions.
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Cut
Cut the new polycarbonate sheet to size. Sand the edges and apply primer.
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Sand
Sand and degrease the rebate. Tape off strategic areas.
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Bend
Bend the pane, and clamp if necessary during gluing, using spacers for tension.
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Finish
After drying, remove the spacers, protective film, and tape.
Ron’s tips for others
“Always wear protective gloves when working with Sikaflex. As the adhesive and primer are difficult to remove, it is essential to tape off anything that could come into contact with them. This project is not easy and requires a lot of time.”
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