Clear Polycarbonate Windows for Southerly 115 Yacht

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
Remove
Cut
Sand
Bend
Finish
Supplies

Tools
- Stanley knife
- Sharp knife
- Chisel
- Jigsaw
- Angle iron (guide saw)
- Dremel with sanding attachment
- Fine brushes for primer
- Sealant gun
- Plastic spatulas
Materials
- Primer Sikaflex Primer 209 N, 2 x 30 ml
- Marine adhesive Sikaflex-295 UV, 300ml
- Painter’s tape
“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.”
“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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