How to: Replace non-square windows

From Willow in BC, I got a very sensible reply to the question I posted on sailboat owners.com:

• I had them cut the plexi to the same shape but 1" larger all the way around.
• I drilled holes about every 6" around the perimeter of the pieces, 1/2" in from the edge, and
• screwed them to the outside of the cabin.
• I sealed with 'Dow Corning 795' on the advice of a local boatbuilder.

This way I retained the distinctive window shape, removed a source of leaks (the old windows leaked between the frame and the lens), and updated the look of the boat significantly.

Sound slick. She says the whole thing took just a few hours.

Note: after reading some of the documentation on this adhesive/sealant, I'll mask off the frame, since the weakness in my hands makes it impossible to apply a straight bead.

Complete instructions for the overstressed:

1. Cover cabin & remove old windows.
2. Take to TAP and have them cut new ones that are 1" larger at each edge.
   
3. Prep surfaces. Sand as needed, and use non-oily SOLVENT, not water, to clean the surfaces.
   
4. Template existing holes, if any, in cabin top.
5. Mark outline of new windows on cabin's outside surface.
   
6. Drill windows to match template, or every 6" if no existing holes.
1. If there are no existing window holes in the cabin top, drill holes to match those in the window.
   
7. Mask off 1/4" outside the edge of window outline.
   
8. Wipe exposed area with clean dry cloth; no oil, soap, or water.
   
9. Apply sealant and flatten slightly, so it goes up to masking all around and to 1/4" inside window line as well. Use FRICTION to help smooth it along; no water.
   
10. Screw in windows.
11. Remove masking tape.

It takes a few weeks to cure fully, but I imagine the boat will be sailable in a few days.

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