How to Make a Windshield for a Boat

Making your own windshield for your boat is an inexpensive way to replace a broken or missing one. This article will take you step by step to your finished project.

Difficulty: Moderately Challenging

Instructions

Things You'll Need:

• 1/8 inch Lexan slightly larger than windshield you want to replace
• Heat gun
• Clean rag
• 2 five gallon buckets
• utility knife
• Craft paper if desired
• Safety Glasses

1. 
    
   A box works well to carry the small items

   Assemble items before starting this project. Make sure that you have adequate space to work on this project.

2. 
    
   Craft paper is an inexpensive item.

   Use utility knife to trim the shape of the windshield that you want from the Lexan. Use craft paper for template if needed.

3. 
    
   Utility knives are sharp!

   Work slowly while trimming to make sure that you get a nice, clean line. Cut away from you if possible.

4. 
    

   After cutting, wipe Lexan to remove fingerprints from the Lexan. Keep the rag hand in case that you touch the Lexan.

5. Set the trimmed Lexan over the buckets with the buckets at the end.

6. Slowly heat the Lexan with the heat gun being careful to have it at the lowest setting and not directly on the Lexan.

7. If necessary practice on a scrap piece to get the right temperature and angle

8. Slowly work the ends of the Lexan until they are to the right shape.

9. Cool slowly and thoroughly before attaching it to your boat.

Tips & Warnings

• Do not point the heat gun directly at the surface.
• Be careful to remove all fingerprints or they will be ingrained on the Lexan.
• Always wear safety glasses to protect your eyes.
• Utility knives are sharp. Be sure to cut away from your legs.
• Heat guns get very hot. DO NOT TOUCH END.
• Do not touch the Lexan until it is totally cool.

[robnmegfuller]

on 4/23/2009 A bit difficult, but with some practice I was able to make an inexpensive replacement for my boat.