Re: polycarbonate window thickness?
I have used a router to cut it using the old piece of plastic as a template with the two sheets held together with double-sided tape. It is not too hard to work with normal woodworking tools.
Back to Grenada in early December. Not sure I will remember how to sail. Will spend the winter and early spring in the Caribbean and then head to Bermuda and the northeast US. Still trying to decide if we will bring the boat to Canada, either in 2015 or 2016.