Omar Khalid
Boat owners often choose to repair their windshields themselves, using affordable materials such as Lexan glass and Plexiglas. The process involves cutting the plastic to the right shape, forming a curve using heat, and drilling holes for attachment. While it is possible to bend and shape Plexiglas at home, it is a challenging process that requires careful execution to avoid scratching or damaging the surface. Lexan is a more expensive but stronger alternative that is less prone to scratches and easier to bend without cracking.
| Characteristics | Values |
|---|---|
| Materials | Acrylics, Polycarbonates (Plexiglas, Lexan) |
| Thickness | 1/4" or 1/8" |
| Process | Cutting, Bending, Drilling, Sanding, Buffing, Riveting |
| Tools | Table/Band/Handheld Saber Saws, Carbide Blades, Heat Guns, Rotozip Tool, Sheetmetal Brake, Soldering Iron, Drill Bits |
| Suppliers | Lowes, HD, EBay, Local Plastic Suppliers, Marine Stores |
| Cost | $80-$100 for custom windshield, $100-$130 for self-cut sheet, $200+ for heated and formed sheet |
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What You'll Learn
Choosing the right material: Lexan or Plexiglas
When it comes to choosing the right material for a boat windshield, two types of plastic are commonly used: Plexiglas (acrylic) and Lexan (polycarbonate). Both materials are well-suited for boat windshields, but there are some key differences to consider when making a choice.
Plexiglas is generally the more popular choice among boat owners, as it is more readily available and easier to work with. It is also less expensive than Lexan and is less prone to scratching. Plexiglas can be cut to size using various tools, such as table saws, band saws, or handheld saber saws, and it comes with protective paper on both sides to prevent scratching during the fabrication process. However, one disadvantage of Plexiglas is that it is relatively harder to seal than tempered glass, and certain sealants, such as those containing solvents, can be detrimental to Plexiglas.
On the other hand, Lexan is the more expensive option, but it offers greater strength and durability. It is more scratch-resistant than Plexiglas and is better at resisting UV-induced discolouration (yellowing). In applications where strength is critical, such as fitting windows and ports on a blue-water vessel, Lexan may be the more appropriate choice. Additionally, Lexan is available with coatings to enhance its performance, although this further increases the cost.
Ultimately, the decision between Plexiglas and Lexan depends on specific requirements and budget. For recreational marine applications, Plexiglas is often sufficient, offering adequate strength, low maintenance, and longevity at a lower cost. However, for more demanding applications or where strength is a priority, Lexan may be the preferred choice.
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Cutting the plastic to size
If you choose to cut the plastic yourself, there are several tools you can use. Plexiglas can be cut using table saws, band saws, or handheld saber saws. When using a table saw, it is important to use carbide blades with fine teeth. Regardless of the type of saw, it is crucial to cut slowly to avoid overheating the plastic, as this can cause it to melt and reform behind the blade. Cut slightly off the line to allow for edge finishing.
It is also important to note that Plexiglas comes with protective paper on both sides to prevent scratching or damage. Leave this protective paper on until you are finished cutting and ready to begin finishing the edges. Even with a fine blade and a smooth cut, the edges of the plastic will need to be sanded and polished to prevent micro-cracks from forming and eventually developing into full-blown cracks. Start by sanding the cut edge with 80-grit sandpaper to remove saw marks, and then gradually move to finer grits to sand out the previous grit's marks.
Additionally, when creating a plastic boat windshield, it is essential to make accurate measurements of the window size and thickness to ensure a proper fit. You may also need to create a form or mould to heat and bend the plastic to the desired curve, as simply cutting and mounting flat pieces of plastic may not result in a functional windshield.
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Bending the plastic
Bending plastic for a boat windshield requires careful preparation and execution. Here are the key steps and considerations for this process:
Choosing the Right Plastic
Select a suitable plastic material for your windshield. The two most common options are acrylics (known as Plexiglas) and polycarbonates (known as Lexan). Plexiglas is more affordable, easier to work with, and less prone to scratching, while Lexan is stronger and more scratch-resistant but more expensive. Consider your budget, the level of ease in working with the material, and the desired durability of your windshield.
Preparation and Measurement
Before bending, ensure you have accurately measured the required dimensions for your boat windshield. Measure not just the glass size but also the thickness of the window and panel to find a seal with the correct fit. This step is crucial to ensure a proper fit during installation. Additionally, make a template or pattern for your windshield to guide the bending process.
Bending Process
The bending process involves the application of heat to the plastic to achieve the desired curvature. Here are the detailed steps:
- Use a Heat Gun: Obtain a heat gun, which is inexpensive and readily available at hardware stores. You will use this to heat the plastic and make it pliable for bending.
- Protective Covering: Ensure the protective paper covering is still attached to the Plexiglas during the bending process to reduce the risk of scratching or damaging the surface.
- Heat Application: Lay the Plexiglas over a cardboard tube with a diameter of about 12 inches, secured at the edge of your workbench. This will help create the desired curvature. Heat the area you want to bend, along with an additional four to six inches beyond it, using the heat gun. Be careful not to stay in one spot for too long, as it may cause the plastic to melt.
- Applying Pressure: As the plastic starts to soften and bend, you can assist the bending process by applying slight pressure. Use the weight of the Plexiglas itself to help with the bending. Be patient during this step, as it may take a few hours to achieve the desired bend.
- Cooling and Clamping: Once you've achieved the desired bend, allow the plastic to cool. You may want to clamp the plastic to help it retain its shape as it cools. It's normal to hear a slight cracking sound during the cooling process.
- Finishing the Edges: After bending, the edges of the Plexiglas will need finishing. Start by sanding the cut edge with 80-grit sandpaper to remove any saw marks. Progressively use finer grits to sand out the previous grit's marks until you achieve a smooth finish.
Additional Considerations
- Oven Alternative: Some people have suggested using an oven to heat the plastic for bending. However, this method is generally not recommended due to the size of the oven required and the potential for uneven heating.
- Warping and Cracking: Be cautious when bending plastic to avoid warping and cracking. Polycarbonate Lexan can be bent pretty well cold, but acrylic Plexiglas has less formability and may shatter if stressed beyond its limits.
- Sealants: When installing your new windshield, choose the right seal for the material. Lexan glass and Plexiglas can be challenging to seal, and certain sealants may negatively affect the seal or cause leaks.
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Drilling holes
Choosing the Right Tools and Materials:
- Select the appropriate drill bits: When drilling into plastic, it is recommended to use drill bits specifically designed for plastic. These bits typically have 60-degree tips and are less likely to "walk" or move unexpectedly during drilling, reducing the risk of cracking the plastic. Standard metal drill bits can also be used, but they require more care to prevent walking.
- Opt for sharp drill bits: Ensure that your drill bits are sharp. A sharp bit with the proper angle will make cleaner cuts and reduce the risk of cracking or chipping the plastic.
- Choose the right sealant: Consider the type of plastic you are using for your windshield. For example, Lexan glass and Plexiglas are relatively harder to seal than tempered glass. Choose a sealant compatible with your plastic type to ensure a proper seal and avoid leaks.
Preparing for Drilling:
- Make accurate measurements: Before drilling any holes, take precise measurements of your windshield and mark the exact locations for the holes. This ensures that your holes are drilled in the correct positions.
- Drill oversize holes: It is recommended to drill holes slightly larger than the standard requirements to accommodate movement due to temperature changes. This helps prevent cracking in the plastic as it expands and contracts.
- Practice on a separate piece: If possible, practice drilling on a separate piece of similar plastic before drilling into your actual windshield. This will help you get a feel for the process and make any necessary adjustments.
Drilling the Holes:
- Take your time: When drilling into plastic, it is crucial to go slow. Drilling too fast can generate excessive heat, causing the plastic to melt or crack. Take your time and apply light pressure to maintain control.
- Use a steady hand: Hold the drill steadily and perpendicularly to the plastic surface. This helps ensure that the holes are drilled straight and reduces the risk of the drill bit walking.
- Clean and finish the holes: Once you've drilled the holes, use a razor blade or similar tool to trim away any excess molten plastic. Deburr and polish the holes carefully to remove any sharp edges or stresses that can lead to cracking over time.
Remember, drilling into plastic requires patience and precision. Take your time, follow the instructions provided by the plastic manufacturer, and practice on scrap plastic whenever possible to ensure a successful outcome.
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Sealing the windshield
Cleaning and Preparation:
Before sealing, it is essential to thoroughly clean the surfaces of the windshield and the boat. Remove any old sealant residue with a paint thinner and scrape away any corrosion with sandpaper. This step ensures that the new seal will adhere properly and not be affected by contaminants.
Choosing the Right Sealant:
Select a suitable sealant for the material of your windshield, whether it is Lexan, Plexiglas, or another type of plastic. Polyurethane sealants, for example, may cause outgassing issues with plastic, leading to leaks. Sealants containing solvents should also be avoided when working with Plexiglas. Tempered glass is generally easier to seal than Lexan or Plexiglas.
Measuring and Fitting:
Accurate measurements are crucial. Measure not only the glass size but also the thickness of the window and panel to ensure a proper fit. Make sure to create substantially oversized holes to prevent the glass surface from cracking. When using a 1/4" screw or fastener, for instance, the hole should be 7/16".
Sealing Techniques:
There are different techniques for sealing the windshield, depending on the material and your specific application. One common method is to use a gasket or trim to seal the edges of the windshield. You can purchase gasket material from suppliers like Amazon or eBay, or from marine supply places. Another technique is to use a sealant or adhesive specifically designed for the material of your windshield. Follow the manufacturer's instructions for proper application.
Drilling and Fastening:
When drilling holes for fasteners or rivets, use a sharp, normal high-speed drill bit. Go slowly to avoid softening and clogging the bit, which can lead to shattering the plastic. Sand and polish the drilled holes to ensure there are no sharp corners and scratches. Some people also recommend using a soldering iron to melt through the plastic instead of drilling.
Bending and Forming:
If your windshield requires bending or forming, be cautious with heat guns as they may cause unevenness. Consider using a form made of wood, sanded smooth, and placed under heat lamps to allow the plastic to sag into shape. For Plexiglas, heat forming is often necessary to create curved sides. Polycarbonate, on the other hand, can be cold-bent without breaking.
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Frequently asked questions
You can use either acrylics or polycarbonates, commonly known as Plexiglas and Lexan. Both materials are sold in a wide variety of thicknesses, colours and sizes.
You can buy large sheets of Plexiglas at Lowes or HD. You can also find suppliers on eBay or at local plastic suppliers.
Plexiglas can be cut using table saws, band saws or hand-held saber saws. When using a saw, remember to go slowly to avoid overheating the plastic, which will cause it to melt.
You can shape the plastic by heating it. First, cut the plastic to the right shape, then create a form for the curve, usually out of thin plywood covered with cloth. Then, heat the plastic until it sags over the form and let it cool. You can use a heat gun to heat the plastic, but this can cause unevenness.
