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post #1 of 15 Old 07-09-2012 Thread Starter
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Custom cut round plastic window for forward hatch

The hatch on my boat has a round plastic window (plexiglass or polycarbonate, not sure which) and as I understand it didn't hold very well in place and it was accidentally dropped overboard while cleaning, so we need a replacement.

Does anyone know a good place that can create custom cut window?
And what is better - plexiglass or polycarbonate? The window will be stepped on, so needs to be strong.

And the shape is like this - upper diameter is 16 1/2'', lower is 16 1/4'', the top is 1/8'' in height and the cut is 1/8''

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post #2 of 15 Old 07-09-2012
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Re: Custom cut round plastic window for forward hatch

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Originally Posted by Romario View Post
The hatch on my boat has a round plastic window (plexiglass or polycarbonate, not sure which) and as I understand it didn't hold very well in place and it was accidentally dropped overboard while cleaning, so we need a replacement.

Does anyone know a good place that can create custom cut window?
And what is better - plexiglass or polycarbonate? The window will be stepped on, so needs to be strong.

And the shape is like this - upper diameter is 16 1/2'', lower is 16 1/4'', the top is 1/8'' in height and the cut is 1/8''

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Any plastics shop should be able to do this for you. I'd recommend acrylic (Plexiglass) over Lexan - Lexan is more expensive and scratches more easily and Plexi is plenty strong enough - most hatches use plexi when manufactured.

If you know the make of your hatch you might be able to get a replacement lens from the manufacturer.

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post #3 of 15 Old 07-09-2012 Thread Starter
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Re: Custom cut round plastic window for forward hatch

Not sure about the manufacturer, the boat is O'Day 30. Do you think 3/8'' is enough thickness to withstand people standing on it?
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post #4 of 15 Old 07-09-2012
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Re: Custom cut round plastic window for forward hatch

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Not sure about the manufacturer, the boat is O'Day 30. Do you think 3/8'' is enough thickness to withstand people standing on it?
Just replace it with whatever thickness it currently is. 3/8" plexi is plenty strong - that's what most hatches seem to have in them. Perhaps Deniseo30 can help - she has an O'Day 30

By the by, walking on hatch lenses is not a good idea - they get scratched and they can be VERY slippery when wet.

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post #5 of 15 Old 07-17-2012 Thread Starter
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Re: Custom cut round plastic window for forward hatch

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Just replace it with whatever thickness it currently is. 3/8" plexi is plenty strong - that's what most hatches seem to have in them. Perhaps Deniseo30 can help - she has an O'Day 30

By the by, walking on hatch lenses is not a good idea - they get scratched and they can be VERY slippery when wet.
The one that was there got lost - my gf was cleaning and it looks like it wasn't held in place very well, so it got overboard.

I know it's not a good idea, but sometimes guests might step into it and I don't want them to fall through.

I actually sent the message, trying to get a quote, so far only got one answer and the price is $200 - pretty steep for a small piece of plastic.

Do you think it will be hard to cut it by myself? I remember we cut organic glass without much problem, the only thing is - how do I make the ridge.
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post #6 of 15 Old 07-17-2012
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Re: Custom cut round plastic window for forward hatch

Maritime Plastics in Annapolis or Piedmont Plastics - various locations
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post #7 of 15 Old 07-17-2012
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Re: Custom cut round plastic window for forward hatch

I highly recommend Select Plasrics in Brooklyn, NY. They are right under one of the elevated subway lines, a stop or two from Flatbush Avenue (Atlantic Terninal) station, behind a very non descript door. (Check to make sure you got the right "select Plastics". I think there may be 2 of them.)

I got 16x18 lenses of Polucarbonate for $90 each. And I got it slighty thicker than what was there originally.

They have a computer cutting table that does the actual cutting. (If you had the old lens, it would be a big help, of course.)

Regards,
Brad
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Re: Custom cut round plastic window for forward hatch

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Do you think it will be hard to cut it by myself? I remember we cut organic glass without much problem, the only thing is - how do I make the ridge.
Plexi is easy to work with woodworking tools. Cut the disk with a jigsaw with a plastics blade, sand the edge smooth and then rout the lip (ridge) with a bearing pilot router bit. Using a router table helps a lot. Any good tool store will have an appropriate rabbeting bit.

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post #9 of 15 Old 07-18-2012
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Re: Custom cut round plastic window for forward hatch

You can also get UV coated acrylic which probably makes sense to stop it from crazing in the long run. I used it to replace all my big salon glazing units and it is holding up well after 3 years. +1 on cutting it yourself. If in a hatch, it needs something other than just sealant to keep it in place.

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Re: Custom cut round plastic window for forward hatch

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If in a hatch, it needs something other than just sealant to keep it in place.
Dow Corning 795

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