Manufacturing Replacement Marine Windows for Sailboat Refurbish

The Challenge:

A Rhode-Island based sailboat owner was rebuilding his boat and needed to replace all the windows within the cabin area that were severely pitted and scratched from years in salt water and weather. They were so worn, a person couldn’t see outside beyond shapes and light.

The owner reached out to Derecktor Design to have new windows custom built to fit the existing openings. Here is how we did it…

Different Shaped Cabin Windows

Old Rounded Rectangle Window

Old Angled Window

How We Approached the Task of Prototyping and Building the Replacement Windows

Prototype: To prototype the replacement windows, we first optimized the waterjet file based on the rough templates provided by the owner. This involved ensuring that the waterjet would cut the windows to the correct size and shape and that the screw holes would be in the correct locations. Next, we cut a sample part out of less expensive wood to test fit the windows within the frame on the sailboat.
Material Selection: In order to ensure that the replacement sailboat windows would perform flawlessly in their intended environment, we selected a marine-grade polycarbonate material that is highly resistant to ultraviolet light and scratching. We were able to source this material from a local supplier.
Waterjet Cutting: Once the client confirmed that the fit was correct and approved the material, we cut the six new polycarbonate windows on our waterjet machine, where the high pressure water and garnet abrasives cut both the window shapes and screw holes.
Mounting Screw Hole Chamfers: Finally, we used our Bridgeport mill to chamfer the holes so the screws mounting the windows to the cabin would fit flush to the window surface after installation was completed.

Waterjet Cutting the Windows

Here is a look at one of the new sailboat windows fresh from cutting on the waterjet machine right after the process (it’s a messy job!).

…and here’s one all cleaned up after the waterjet cutting.

Screw Hole Chamfer

Hole chamfer underway to allow the mounting screws to fit flush to the window surface.

Windows Installed in the Sailboat Cabin

What a Difference!

How Can Derecktor Design Help on Your Next Project?

Reach out today to our machine shop, engineers and marine experts. We are ready to help you design, engineer, build, test, and manufacturer your product or project!