Q2 - 2025
Boat with polycarbonate window
Submitted byJaap
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
1
Build frame
Build a wooden frame of the boat as the foundation.
2
Cover frame
Cover the frame with panel material and laminate it with multiple layers of glue.
3
Apply fibreglass
Apply a layer of fibreglass and epoxy for strength and waterproofing.
4
Fill & sand
Fill and sand everything smooth.
5
Paint
Paint the boat in six layers for a great finish.
6
Fit window
Design the window in AutoCAD, have it made from 5 mm polycarbonate, and fit it.
Supplies
Polycarbonate clear 5 mm
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.
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.
DIY Awards
Discover more inspiring projects submitted for the DIY Awards.
Smart window insulation for listed buildings with polycarbonate
Jan from Amsterdam has come up with a clever solution for his historic building. Legally, he cannot alter the windows, …
Smart window insulation for listed buildings with polycarbonate
Jan from Amsterdam has come up with a clever solution for his historic building. Legally, he cannot alter the windows, …
Share this article
