I'm going to try to keep a monthly topic going so that everyone has time to get, or put in their two cents worth. The most important thing is support for each other. My way aint always the right way. My way has, however, stood up to -30 degrees F to +80 as Inkslinger was a "TOP OFF" refit done in Alaska. So.......If nothing else perhaps you'll have a few good ideas to share too.
So.....About those pesky smoked plexi windows. We call em Portlights but us Reinellers have big'uns so windows will do. Mine were the original smoked plexi of 1/8 thickness and were shaped for a slight bubble look and, with 30 odd years of every sealant known to man used to try to abate the flow of water, needed replacement. I used one of the old ones (you know...the one that didn't break during removal) as a patern on the OH MY GOD expensive 1/4"sheet of Polycarbonate, or as we like to call LEXAN. At $388.82 for a 4'x8' sheet that follows the market like precious metals, you DO NOT MAKE MISTAKES!
Preparation for the cabintop was to dig out the rotten balsa back aways, 1 1/2 " in Inkslingers case, and fill the void with Kitty Hair (Long strands of glass in a resin base) then the sill edge was sanded sealed painted etc.
The trim is Oak and routed out for the lexan to sit in for the outside surface and just solid for the inside.
Then, after staining/sealing etc. It is installed to the cabintop using urethane sealant that has to be heated to 170 degrees F. and held every 6" by 1/4"ss carriage bolts. NOTE: The lexan must be overdrilled to 3/8" for expansion and contraction.
