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I need to replace two of the internal window frames for my Chris Craft Apache 37 sailboat, one was cracked and another broke a piece off when I removed them to replace the lexan on the main salon ports.....

any suggestions? They appear to be 3/4" wide rounded aluminum about 3/16" thick -- can I find anything like this already made or am I going to have to get it machined, if I am getting it machined and guestimates on a cost range? Never had anything made before and have no idea what a reasonable cost is

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I can't help you regarding the metal, but my brother is working on making a template for a local word working shop, and they are going to make some out of mahogany. I have a similar issue, and I just figured wood would look nicer.

I'll bet there is a word working shop local to you yhat can make you up something nice, if you want wood.
 

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I see in a photo that there are 4 portlight frames on an Apache so I understand why you would want aluminum. I would guess that they are fairly expensive to fabricate but who knows? I have had metal parts fabricated before and they have never been cheap. 4 new ones in wood as jarcher suggests or starboard (plastic) are probably less expensive than 2 in aluminum and you can make them yourself if you are handy. Or maybe there is a trade school in your area that would like to take on a metal project and build them for you.
 

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I have seen people use lexan and make the new window larger than the opening and somehow decoratively screw it onto the opening. THis is a good safety issue too as a breaking wave will have difficulty pushing the window in. If that is a concern of yours.

There is also the car rubber windshield stuff. But that will probably need a window smaller than the opening. and be possible for the above wave to knock it in.

I have heard of the rubber gasket stuff that has offset grooves and allows the window to be larger than the opening.
gh
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