Fixed Window Replacement

[Crazy Dave Condon]

@SV Temenos

Contact Al Fooks at this forum store. He has the designs, build list of parts, etc for the hunter sailboat. In fact, Al worked building their boats Al worked in warranty and then customer parts. As a former employee r for Hunter, he knows windows particularly with curves and so on. I found the windows to be property being cut and curved if any. Generally, their prices were in line and many times k lower than others. Cal Al.

 

[dLj]

TAP plastics sells sample pieces cheap.

I think it would be easier to do the bevel with a router (many libraries will lend you a router or other tools.) Mine were a bevel, but I like the round over better.

I do lots of woodwork using routers. I have bad luck with plastics. I tend to end up almost done and then bam! I burned the last bit... However I've recently acquired a fence with a micrometer adjustment. I'm hoping that cures the problem.

dj

 

[SV Temenos]

I thought a picture of one of my windows would help show the type of cut I will be making:

 

[dLj]

That's a steep bevel... I'd definitely cut that with my jig saw. I'd take a piece of 2X4 or 2X6, run the short edge through a planer/jointer to make a nice flat surface. I'd then clamp that to the backside of the window so I had a nice stable surface for my jig saw base. I'd set my jig saw to the correct angle and cut each of the bevel sides that way. Then finish it up using a sander. You can shape the corner in that step. You'll end up with a much nicer looking bevel in the process...

dj

Don't take any paper off the part until it's completely finished... You can use lines on the paper to help guide your cut.