Both port and starboard windows were replaced with 2 custom alumn framed windows each side. Windows were ordered from a company in Canada who were very helpful in window selection and sizing, they will build any size window so was not limited by trying to fit a stock window dimension to fit a custom design. The window mfgr also offered glazing in Lexan or safety glass, after several discussions with them chose 5/16 tinted safety glass, both materials have good points.

Original Port Side Window

Existing Lexan window removed and all existing fiberglass was cleaned to remove mold-release wax then disc sanded with 80 grit sandpaper to create a good mechanical bond for new glass work. Used West System epoxy and glass cloth to build out the area to the new window dimensions.

Lexan Window Removed and Area Prepd

Fiberglass was built out useing West System epoxy and finished with gelcoat sprayed on. Epoxy was tinted white during the build-up to help final gelcoat color match. Final gelcoat was sparayed on then wet sanded up to 1000 grit then machine polished with 3m rubbing\polishing compound then waxed.

Fiberglass Reformed to New Window Dimensions

New gelcoat was carried well into existing areas such as up to non-skid lines and over to aft port-lites to better blend new to old. Entire cabintop was then polished with 3m finishing polish then waxed so its nearly impossible to find where new gelcoat blend to old. I think changing from one long window to 2 windows each side greatly enhanced the boat appearance.

Final Exterior View

Interior had previously been redone to cover exposed fiberglass so didnt have to do any fiberglass interior work because the new windows were intentionally ordered to cover repaired areas.

Finished Interior