Hello again John,
Our companionway panel is in 6mm thick clear perspex. which you should be available to source from any window conservatory manufacturer - a high proportion of windows in schools and industrial units (I used to work for a building contractor - still do on occassion) use perspex for at least one skin of double glazed window units nowadays and virtually all non-domestic rooflights are perspex.- the transparency isn't quite as good, but they offer far better resistance to accidental damage and vandalism. Indeed, you'll probably find that any local glazier can supply perspex and cut it to shape up to 6mm thick.
All I did to the edges was sand off the sharp corners and apply some self-adhesive sealing tape (as used for cockpit sole) to the long edges, to prevent it from rattling in its slot on windy days.
No lifting handles - it probably weighs less than 2kg.
Ours is a low-tech and to be honest low security option, which we use to let light in and keep the cold out when at anchor - we almost always fit the timber washboards, or on hot days a welded heavy duty stainless steel welded mesh (that lives under the port saloon cushion) infill panel when we go ashore.
If you're wanting a more secure/permanent installation, still try your local glazier first, as an increasing proportion of new shop-front display windows (particularly those located near busy pubs and nightclubs) are now fitted with 8/10/12mm perspex panels. Whilst these thicknesses are not always available off the shelf, unless your local glazier goes in for commercial emergency glazing repairs, he should still be able to source them in a couple of days.
Bob Carlisle.
