I have a 2007 41AC and I have had to replace all of the acrylic panels due to cracks developing. I removed the acrylic panels to the local TAP Plastics store and they cut new ones for me - in some cases, they cut them while I waited (10 minutes at most). If you live near a medium-sized city or larger you can probably find a similar plastics store that can make them for you. It is a relatively simple process to remove the panels by cutting the silicone sealer with an Exacto knife. Re-bedding them with Dow 795 is fairly easy, too. Prepping the frames for re-installing the acrylic panels is probably the most difficult as you need to remove all traces of the existing silicone before proceeding. There are solvents that you can buy that are specifically for removing cured silicone.
Currently, I'm in the process of replacing the acrylic panel in one of the windows in the galley. The biggest issue is dealing with the three hinges across the top. The SailboatOwners store sells replacement hinges that attach to the acrylic panel using screws but mine are attached using some sort of solvent. I have been able to remove the existing hinges by milling away most of the acrylic from the opposite side where the hinges attach and then breaking out the hinge. A little work with a grinder, sander and file removed the small amount of acrylic remaining on the hinge pieces. I have purchased a solvent that is supposed to work with acrylic and ABS that I believe will work to reattach the hinges but I will probably also use a machine screw just to be certain.
