Hey,
We're in the process of changing the lexan windows on our boat. Probably doesn't warrant a blog, but I feel the need to vent, since, like every other chore on a boat, this one's taking five times longer and is way harder than planned. First we made templates out of bristol board, took them to the Plastic Shop, and they did a great job of cutting new ones. The old ones, which we also put in ourselves twelve years ago, have become too milky to see through. They were laid onto a thick layer of caulking, and screwed to hold them while the caulking set up. They were fairly difficult to remove, with prybars, etc., and then getting the caulking off the frame took about two hours per window (six). Then we decided not to have screws this time. We're going to mount them with double-sided glazier's tape, and then caulk the edges. So we had to fill the old holes, and the nicks and scratches, using thickened gelcoat. That's where we are now, stopping for the day. Hope to install and caulk tomorrow.
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