SUJET :

I am making new windows for my 1090, from the correct 12mm Perspex material.

I have made the drawings, and I have the machinery to make these pieces, and will be applying the correct procedure to make the curve on the front windows etc.

Because the material is to be purchased in large piece (2m x 3m) I have material to make some extra windows. If other owners of Feeling 1090 needs one or all window, I can make from the extra material, for a price much less than the commercial price ... you can choose if it is made with or without the holes.

If there is any interest in this, please let me know ...

An interesting point ... when rmoving the window, I used a knife to cut the adhesive ... I was expecting the knife to stop where there is the screws, but in most cases, it did not stopped ... it passed though .. the reality is the screws had completely corroded. Nothing remained of the screw inside the window, just a white dust ...

The process has started ... the plastic and wood is all being replaced.

The port lining is made, routed on the CNC, veneered in European Elm .. looks good.

I'm going to have the same job to do on mine, I can be interested by the windows ... but I thought to make them in two pieces because mine are broken and I think in one piece the constraints are more important.
I forgot to mention that I have a feeling 920, I'm only looking for plexi!

I am making the plexiglass for mine ... it is not a simple job.

For the side, it is easy ... 10mm plexiglass, no problem. I would think to make only in one piece ... if manufactured in 2 pieces, it is another place for the water to enter. I will not pu holes in mine, I will seal direct, with Sikaflex 295 UV

For the front, it is difficult ... 12mm plexiglass, it is bent or formed with heat ... a form has to be made for the exact shape, and the plexiglass heated in an oven.

I will post photogrpahs of the process. I do no have the drawings for the 920, only the 1090, so I do not think I could help with making these ...

and the work continues ...

The final panel is drawn .... this completes all the measurment, next is the fabrication.

The first pieces of the lining are replaced ... the colour difference is amazing. When you compare the new white to the old white .. it had become brown with years. The light is not good in these photos, the result is better than it looks in the image.

Soon we start positioning the new woodwork.

And today, the new Perspex arrives ...

And, the windows are cut ... now I have to put the front window in an oven to make the correct shape ..

Sir,

the result is marvelous.

how did you proceed? I see a iron, so is it veneer ?

If yes, what plywood do you use ?

do you have the address where to find such veneer ?

Thank you for your help; I have the same thing to do.

Alain sailing on Posidonie

Yes, it is veneer, I get the veneer from here:

www.capitalcrispin.com/item.php?id=TLmuoM4hzF

It is "European Elm, Straight Cut" ... the pieces are ~ 3m x 0.2m

The glue is iron on. It is a sheet. The technique is first you place the sheet on the plywood and lightly fix with the iron. Then, remove the paper. Place the veneer on the glue, make the arrangement and finally press with the iron. Use some clean paper so the iron does not mark the veneer.

The glue sheet is here:

www.woodveneer4u.co.uk/WoodVeneerAdhesives.html

The plywood is good quality hardwood ply. It is not expensive "marine ply" because it should not be in the water (I hope!) .

All the wood is cut on my CNC router ... it is much easier than cutting by hand. If you need the drawing, let me know.

The last piece is cut, tomorrow it will get the veneer.

So, the final piece is veneered, I put some photos of the process.

And the first coat of varnish is applied ...

Today, the first panel was replaced!

Some hours with clamps and epoxy ... and some work with the router, but now it is ready to receive the Perspex on the outside.

And the first window is complete!

And from outside, with the clean form it looks very nice. No screw holes is a big improvement I think.

We used Sikaflex 295UV with Sika 209D primer. 2 windows are now installed, next is the front window, which I need to heat in the oven ...

dear Robin,

I Follow your work and it's very professional and well done.
Could you send me the file with the measurment, because I had to do the same.
Have you find Cleat beside the pannel and do you have there measurment ?
I found a factory for the plywood.
What sort or wood will you use for the edges ?

Thank you for your help.
I Think that at the end it's will be like a new and may be best than a new.

Alain on Posidonie

Hello Robin,
your explanations and pictures are excellent and very interesting for everyone. So, I propose to write an article about it. If you agree, Alain Dugast (our publisher) can do it, when your forum posts are completed.
Cheers