So 1/2 of the newest project I am working to finish:
I think they came out pretty nice, although I am not super crazy about the more modern look it gives the boat. I'll have to see it on the water to see how I really feel.
Started by masking things off and trimming it close. Drilled holes, cleaned everything with acetone, applied the 3m 4991 tape and used some finish nails to guide the windows in place. I then caulked it with Dow Corning 795 caulk, worked it in with a plastic spoon. Removed the tape and lightly screwed it on with #8 x 3/4 truss head screws (amazon) in oversize holes with EPDM washers I got from Grainger (EPDM Washer,0.17 IDx0.50 OD,PK100). I'll wait until the silicone cures and then tighten the screws just a tiny bit more.
I just couldn't bring myself to depend on silicon and tape to hold everything together and had to use some screws. I drilled the holes oversize, and installed it around 70 degrees so here in Charlotte, NC that is about mid point on temp range so expansion/contraction cracking things shouldn't be a problem. I was much more worried about the seal for the tape or silicone separating and allowing leaks.
In this last pic you can see how it came out with the automotive exhaust paint sprayed on the inside. It hides all the silicon and tape and really makes it look nice. That was another reason for the screws to be honest. Since the entire bond is dependent on the paint I wanted a little more insurance. I sanded, cleaned and painted well but still. Ignore the slightly sloppy silicon in this pic, I had to remove a really small piece of tape that ripped but it will be easy to clean up after the rest cures.