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11 June 2025

Boat with polycarbonate window

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Jaap has crafted his own boat using wood and a polycarbonate window. The window was specially ordered to size from Plasticsheetsshop, ensuring a perfect fit. Jaap manually built a wooden frame, allowing him to now enjoy his boat on the water.

The Project

Jaap created the boat by first building a wooden frame and then covering it with panel material. He then used fibreglass and epoxy to make it sturdy and waterproof. After filling and sanding, he applied several layers of paint for a beautiful finish. Jaap designed the window in AutoCAD as a DXF file and had it made from 5 mm thick polycarbonate. He chose this thickness to easily bend it to the desired shape.

Step-by-step guide to make this yourself

Build frame

Build a wooden frame of the boat as the foundation.

Cover frame

Cover the frame with panel material and laminate it with multiple layers of glue.

Apply fibreglass

Apply a layer of fibreglass and epoxy for strength and waterproofing.

Fill & sand

Fill and sand everything smooth.

Paint

Paint the boat in six layers for a great finish.

Fit window

Design the window in AutoCAD, have it made from 5 mm polycarbonate, and fit it.

Supplies

Polycarbonate clear 5 mm

Tools

Jigsaw
Sanding block
Sander
Router
Circular saw
Screw driver
Chisels
Handsaw
Filler knives
Scissors
Rollers

Other requirements

Wood
Fibreglass
Filler
Paint

Tips from Jaap

When starting this project, ensure you have a good, large space and bear in mind it could take a year to complete. Also, when painting, make sure the area is really dust-free to achieve a nice and smooth final result.