posted August 22, 2006 01:12 AM            

I really like the look of the Piper when the windows are made tapered in the front, gives it a more modern racy look? so, bingo, I did it.
The job took about two days but it all went very smooth and fitted perfectly.

I started with buying the 3/16" dark grey tinted acrylic sheet from a Toronto supplier, cost about $80.00 including some extra pieces.

Before picture.

I used the original windows as templates then extended the lines to form the tapered extentions with the help of a piece of plastic sheet to mark the curve.

I cut out the shapes using my jig saw with a new blade. Set the jig saw to run at a lower speed otherwise the blade will have a tendancy to heat up and melt the plastic.

After cutting out the windows I clamped the pieces together then used a sharp wood plane to take off the high spots, ten a sander to finish sand the edges.
I bevelled the edges down at a slight angle (to help water run off) then did final sanding to a smooth finish. The smoother the finish the better the end result.
Next step was drilling the holes, first thing you have to do is back the drill point off, this means making the cutting edge of the drill flat on your bench grinder, all you do is touch the cutting edge to the square corner of the grinding wheel so that it takes the edge off flat in line with the drill. The drill will go through like butter and will not take off on you and chip the plastic.
Next I countersunk the holes because I wanted a smooth flush look. Set the depth on your drill press to ensure all holes are the same depth.

[This message has been edited by Kiwi John (edited August 22, 2006).]

posted August 22, 2006 01:13 AM            

Installation:
I used black silicone window sealer, It worked great and sealed perfectly.
I ran a large bead all around the window edge about 3/8" in from the edge circlimg the holes as well, too much is ok because what squeezes out can be easily removed by peeling off when it is partially set up.
I used the corner of a piece of soft plastic to form the finished outside sealed edge.

The installation went very well but you have to be careful when placing the window in place, because, there is a lot of silicone on it and things could get very messy in a hurry.
I was a little concerned that the dark tint would be too dark but it is great, from the inside in the daytime you see everything outside just like sunglasses. The good thing is that nobody can see inside.

These are the new LED nav lights I installed, they are very bright and don't draw much current.

Now the next project!!!!
"Refinish the teak"
Probably next spring.

Comming soon.........
My complete electrical redo revealed, complete with switch panel, power outlets and voltage indicator leds.

Phew!

John

[This message has been edited by Kiwi John (edited August 22, 2006).]

posted August 22, 2006 04:44 AM         

Extending the window shape was brilliant. The workmanship is exceptional. And, the photo essay is well produced too.