Published July 9th 2020

Deja Vu – Sailing Boat Window Replacement:

Fed up with old leaky windows and glass too cloudy to see through, these sailors decided to take on the job of replacing their boat windows themselves, with a great results.

Take a look at this recent transformation that one of our clever customers took on. When Peter and Janet decided to make some improvements to their sailing boat “Deja Vu”, the windows were high on the to-do list. ALFAB supplied the new windows to the specifications provided and this project included removing the old windows, reinforcing the structure around the openings, then installing the brand new ALFAB windows.

While many window replacements are straight forward, this wasn’t a simple swap out and it certainly wasn’t a quick job — it took 9 full working days over roughly 3 weeks to complete. This time frame was to allow for changes in weather, glue drying and creating timber infills to stabilise the window openings, but as you can see in the amazing before and after shots, this project was well worth the time and effort that went into it.

Peter was kind enough to document the entire installation process from start to finish below.





The boat window removal:

Removing the old faded windows was the first part of the process, exposing the surrounding of the old window. Being handy with tools and timber, Peter proceeded to stabilise the 12mm thick cabin top by epoxying 6mm marine ply spacer in the void, which varied, to get it all a constant thickness. Allowing also for a 3-4mm liner.

Removing the old windows

Cabin top void detail

After considering their options for an infill spacer, Peter decided that buying a band saw from Bunnings and cutting timber infills was the best option. They used ¾” self tappers because the infills were 8mm thick. 

Timber trims

Timber trims installed

The boat window installation:

After beginning with 6G screws Peter found some of them stripped the thread so they changed to 8G, tightening them carefully with an electric driver drill on a low torque setting.

Tef-Gel paste was used to isolate the stainless screws from the aluminium frames.

The Butyl tape was very easy to use and time will soon tell how it performs as the weather warms up.

Windows installed

Windows installed








Peter and Janet were very happy with the end result and glad they put in the time and effort to complete the project themselves. The vessel looks great, the view is clear again and there will be no more leaks. Happy sailing!

If you would like assistance with your next boating renovation project, be sure to get in touch with the team of experts at ALFAB in Queensland or Victoria.

For all your marine glazing needs including boat windscreens and windows, our team will provide you with a high-quality finish and professional advice. Contact us today for an obligation-free quote.

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