Replacing Formula Boat Cabin Windows: A Step-By-Step Guide

Replacing the windows of a boat is a crucial part of boat maintenance, as old or damaged windows can compromise the structural integrity and create an uncomfortable environment for those on board. There are several reasons why you might consider replacing your boat's windows, including leaks, cracks or damage, condensation, aesthetics, and energy efficiency. The most common materials used for boat windows are acrylic (plexiglass), polycarbonate (lexan), and tempered glass. When choosing a material, consider factors such as cost, durability, ease of installation, and the overall look you want to achieve. The process of replacing boat windows involves removing the existing windows, measuring and planning for the new windows, cleaning and preparing the window openings, cutting the new windows, dry-fitting the new windows, applying sealant, installing the new windows, and securing the windows with screws or bolts if necessary. It is important to take your time, be patient, and wear safety gear during the window replacement process.

Removing the existing windows

The first step in replacing your Formula boat cabin windows is to remove the existing windows. This process can vary depending on the type of windows and installation method used. Here are the general steps to remove the existing windows:

• Unscrew any fasteners: Depending on the type of windows you have, there may be screws or bolts holding the windows in place. Carefully unscrew these fasteners, making sure not to strip the heads or break the shafts. You may need to use a screwdriver or a drill with the appropriate bit.
• Cut through old sealant: If your windows are sealed with caulk or another type of sealant, you will need to cut through it to release the windows. Use a utility knife or a thin putty knife to carefully cut through the sealant. Be careful not to damage the surrounding surfaces.
• Remove the windows: Once the fasteners and sealant have been removed, you can carefully remove the windows. Use gentle force to push or pull the windows out of their openings. If the windows are stuck, you may need to use a pry bar or a similar tool to carefully loosen them.
• Clean up the window openings: After removing the windows, clean the window openings thoroughly. Use a clean cloth and a solvent such as acetone or rubbing alcohol to remove any dirt, grease, or old sealant residue. This step is crucial for ensuring a strong bond between the new windows and the boat's surface.
• Take measurements: Before ordering new windows, take accurate measurements of the window openings. Measure the length, width, and thickness of the openings, as well as any curves or unique shapes. These measurements will help you order the correct size and shape of windows.

It is important to work carefully and patiently during the window removal process. Boat windows can be fragile, and the surrounding structures can be easily damaged. Always wear appropriate safety gear, such as gloves and eye protection, when performing these tasks. Additionally, having an extra pair of hands to help with the removal process can be beneficial.

Measuring for new windows

Clean the Window Holes:

Before taking any measurements, it is important to clean the window holes to ensure no residue or dirt interferes with the process. Use a clean cloth and a solvent such as rubbing alcohol or a 50/50 mixture of isopropyl alcohol and water to wipe down the area. This step will help achieve accurate measurements and a strong bond between the new windows and the boat's surface.

Determine the Window Size:

Measure the length and width of the window holes to determine the size of the new windows. Be sure to double-check these measurements for accuracy before ordering or cutting the new windows. Additionally, consider the thickness of the window material, as it may impact the overall dimensions.

Original Line Drawings:

If possible, try to obtain the original line drawings from the boat builder. These drawings can provide valuable information about the window specifications, making it easier to order or cut the new windows accurately. Contact the boat builder or manufacturer to inquire about the availability of these drawings.

Choose the Right Materials:

Selecting the right materials for your boat cabin windows is essential. Acrylic (Plexiglass) is a popular choice due to its lightweight, durable, and UV-resistant properties. It is also relatively easy to work with and can be cut to fit your window openings. Polycarbonate (Lexan) is another strong and impact-resistant option but is more expensive and challenging to work with. Tempered glass is a durable but heavier and more costly option. It cannot be cut or shaped after tempering, so ordering the exact size and shape is necessary. Consider factors such as cost, ease of installation, and your desired aesthetic when making your decision.

Take Precise Measurements:

When measuring for the new windows, pay close attention to detail. Measure the length and width of the existing windows and the window openings multiple times to ensure accuracy. Take into account any unique features or shapes of the windows and openings. Consider using a straight edge or ruler to mark cutting lines if you plan to cut the window material yourself.

Consider Shims:

Shims are used to centre the window in the opening and ensure a proper fit. Determine whether you will need shims and, if so, the appropriate size and placement to achieve a secure and centred window installation.

Dry Fit the New Windows:

Before permanently installing the new windows, perform a dry fit to ensure they align correctly with the openings. Insert the windows into the openings and check that the exterior window flange overlaps the opening sufficiently to form a good seal. Make any necessary adjustments to the window size or shape at this stage to guarantee a precise fit.

Remember to take your time during the measurement process and seek assistance if needed. Accurate measurements are crucial to ensure a successful window replacement project.

Cutting new windows

Before you cut your new windows, you must first remove the old windows and clean the window openings thoroughly. Use a clean cloth and rubbing alcohol to remove any dirt, grease, or old sealant residue. This will ensure a strong bond between the new windows and the boat's surface.

If you are using acrylic or polycarbonate material for your new windows, you can cut the windows yourself using a jigsaw or circular saw. Be sure to use a fine-toothed blade designed for cutting plastic materials.

Use a straight edge or ruler and a marker to draw the cutting lines on the material, then carefully cut along the lines. Smooth any rough edges with sandpaper or a file. If you are using tempered glass for your new windows, you must order the windows in the exact size and shape needed for your boat's window openings, as tempered glass cannot be cut or shaped after it has been tempered.

Once you have cut your new windows, it is important to dry fit them in the window openings to ensure they fit properly. Make any necessary adjustments to the window size or shape at this stage.

Tips for Cutting New Windows:

• Use the right tools: Ensure you have the correct tools for the job, including a straight edge or ruler, a drill and drill bits, a jigsaw or circular saw, and sandpaper or a file.
• Take accurate measurements: Measure the dimensions of your existing windows and window openings, including the thickness of the window material. Use these measurements to cut your new windows to the correct size and shape.
• Clean the window openings: Remove any dirt, grease, or old sealant residue from the window openings before installing your new windows to ensure a strong bond.
• Choose the right material: Consider the cost, durability, ease of installation, and the desired look when choosing between acrylic, polycarbonate, or tempered glass for your new windows.

Dry fitting new windows

Before applying any sealant, dry fit the new windows in the window openings to ensure they fit properly. Make any necessary adjustments to the window size or shape at this stage.

For this step, you will need your new windows, and potentially someone to help you out.

Insert the window into the opening to verify whether the new windows fit. The exterior window flange needs to overlap the opening to form a good seal. Pay attention to that. Also, figure out if you will need shims or not. Shims are meant to centre the window in the opening, so it's important to know if you require them or not.

Now, remove the window to prepare it to be installed permanently.

If you are using acrylic or polycarbonate material, you can cut the new windows yourself using a jigsaw or circular saw. Be sure to use a fine-toothed blade designed for cutting plastic materials. Use a straight edge or ruler and a marker to draw the cutting lines on the material, then carefully cut along the lines. Smooth any rough edges with sandpaper or a file.

If you are using tempered glass, you will need to order the windows in the exact size and shape needed for your boat's window openings.

Once you have your new windows, it is time to check whether they fit in the exposed opening or not. If you have someone else around, you may want to ask for their help, as this part is a little difficult to do by yourself.

Applying sealant

Preparing the Surface:

Before applying the sealant, it's essential to prepare the surface for a strong bond. Clean the window openings thoroughly using a clean cloth and rubbing alcohol to remove any dirt, grease, or old sealant residue. Pay special attention to the exterior window flange, ensuring it is free of any residual sealant.

Choosing the Right Sealant:

Select a high-quality, marine-grade sealant that is specifically designed for boat windows. Silicone sealant is a popular choice, such as Dow Corning 795 industrial silicone, as it offers excellent flexibility and watertight properties. Choose a sealant that is UV-resistant and suitable for the material of your new windows (acrylic, polycarbonate, or tempered glass).

Applying the Sealant:

• Apply a generous bead of sealant: Using a caulking gun, apply a continuous and generous bead of sealant around the entire perimeter of the window opening. Ensure that the sealant is applied evenly and that there are no gaps or voids.
• Smooth and tool the sealant: Use your finger or a caulking tool to smooth out the sealant, creating a uniform layer. Tooling the sealant is crucial to achieving a perfect seal. Run your finger or the tool along the sealant, pressing it firmly into place and ensuring good contact with both the window and the boat's surface.
• Check for gaps or imperfections: After tooling, carefully inspect the sealant for any miniature gaps, hairline cracks, or imperfections. Pay close attention to the edges where the sealant meets the window and the boat's surface. Use a bright light or a headlamp to identify any potential problem areas.
• Reapply sealant if necessary: If you find any gaps or imperfections, reapply a small amount of sealant to those areas. Tool the sealant again, ensuring a smooth and even finish.
• Allow the sealant to cure: Once you are satisfied with the sealant application, allow it to cure completely. This typically takes around 24 hours, depending on the sealant manufacturer's instructions. Do not disturb the windows or apply any force during the curing process.

Tips for Applying Sealant:

• Work in a well-ventilated area and wear gloves to protect your hands.
• If you are working in direct sunlight or high temperatures, work quickly as the sealant may start to cure faster.
• If you make a mistake or need to adjust the window position, carefully remove the sealant with a solvent or a sealant removal tool and start again.
• Always follow the manufacturer's instructions for the specific sealant you are using, including curing times and surface preparation guidelines.
• If you are unsure about the process or have any concerns, consult a professional or an experienced boater for advice.

Frequently asked questions