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Old 03-25-2009
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It would seem to be a simpler solution to framing the plexi. I would really like to know how long it would last before trying something like that. It must work reasonably well as lots of manufacturers are doing it even on new boats. But then they also make uni-body Jeeps now too...

They don't really mention it in the article but do they just put the screws into the fiberglass or do they put some wood backing for the screws to bite into? They mention not using nuts because of the issues with cutting the screws to size. After having my plexi inspection hatch start leaking because of screws into fiberglass I am not real eager to repeat that method.

On the plus side of doing the flush mount it would open up more options to finish the inside and would have less cost in materials. when they started to leak or the plastic cracks or hazes it would be simpler to replace it.

After writing this post I am getting more interested in this. I may have to wander down to the plastic place and see how much it would run to put a faux frame on the outside edge to finish it off a bit more.

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Old 03-25-2009
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When I installed the plexi windows on my Oday 20 I used the following to fasten the window to the cabin top.

Stainless machine screws #12 oval head accurate measurement including window and cabin top thickness.

Stainless cup washers

Stainless or nickel/brass barrel nuts on the inside. Prevents you from hitting your head on acorn nuts.

Hope this helps. I would never use a wood style screw to install windows.

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