18 2+3 windshield project.

[problemchild]

The windshield that was custom made for the boat from the previous owner was starting to get old so I made a wood mold and bent some new polycarbonate (3/16" Lexan) around it with slight persuasion from a heat gun. Note that to properly heat this material you should dry it for 12 to 30 hours at 250-150 degrees. Also a heat gun is NOT the recommended tool, although I got away with it. (The last one lasted for 10+ years and was done the same way. I copies the previous windshield because I like the way it looks, it fits with my custom made cover, and I wouldn't have any holes to fill in on the deck of the boat!

Interesting link regarding working with the material:

http://www.curbellplastics.com/technical-resources/pdf/polycarbonate-fab-guide-makrolon.pdf

Here are some pics of the project:


Edit: I'll post them tonight, I can't do it from this computer for some reason.

[problemchild]

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I Traced the top profile and the bottom profile of the existing windshield onto two pieces of OSB Plywood and took height measurements all the way around for the blocking
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As long as you have a good template of the cockpit of your boat and make the size, angle and spacing of your blocks the same, everything comes out perfectly symmetrical. I cut the blocks at 31 degrees for the front and 18 degrees on the sides.

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Test fit

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made a cardboard template from the old windshield

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Traced it onto the polycarbonate. It cuts nicely with a fine blade in a jig saw

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You are supposed to use felt to cover your mold, but I had Tyvek House wrap on hand, which worked nicely to avoid scratching the new windshield during the forming process. Also notice how my audience keeps growing in the pics^^^ apparently my project was the most exciting thing going on last Wednesday night Haha

80032
the material is flexible enough to make the bend w/o heat, I gave it a little heat with a heat gun to help it maintain its shape. in Hindsight the whole mold was probably unnecessary

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Half the windshield installed, I used the molding from the original one. it gets glued and crimped around the top.

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I forgot to take a finished pic, this is of the old one from about 7 yrs ago. The new one came out perfect and I'm extremely happy with it. I'll post a pic when I get back to the cottage.

[Greg Guimond]

That is impressive work you did. I was told that the dimensions and the decks radius crown for an 18 is identical to 16s.

[Ghost]

Wow, that's pretty badass, nice job!

[Conquistador_del_mar]

Very well thought out work procedure and results!

[mattyboy]

I remember this boat, it was in upstate ny the first windshield was really dark tinted I think I have pics of it somewhere

BTW looks great

[problemchild]

Thanks guys,
And yes the boat has always been run in the thousand islands area, thats pretty cool that you recognized it. The original owner was a family friend of ours, my Father tells me that he used to ride in this boat when he was a kid. Floyd sold this Donzi and went to buy a criterion which he had a supercharged big block in. I've heard stories that his best speed was 92 on radar.

[seano]

very cool windshield!

there is a stock one on ebay right now - it's not mine...just thought it post. buy it now looks like $650

http://www.ebay.com/itm/Donzi-18-Stainless-Wind-shield-/261526626600?ssPageName=ADME:B:SS:US:1123

[gcarter]

Good looking windshield!
Well done! :)

[Fishermanjm]

nice job PC... looks awsome

[Scott Pearson]

Add a new Taylor Made windshield gasket and it would finish it off!

[Capevettes]

Very nice job. It looks great.

[osur866]

very cool windshield!

there is a stock one on ebay right now - it's not mine...just thought it post. buy it now looks like $650

http://www.ebay.com/itm/Donzi-18-Stainless-Wind-shield-/261526626600?ssPageName=ADME:B:SS:US:1123

Not anymore

[mattyboy]

I knew I had pics from way back when of this boat the low curved one looks so much better than the hard angles of the newer ones

[OFFSHORE GINGER]

Post # 14 ..................... Matty , i apologize .......but ..............that windshield is but ugly , and not to mention the flack i , most likely will receive from this post ...............

[hardcrab]

Problemchild and Matty, both Very cool lookin' windshield ...... nice / sleek!

[Conquistador_del_mar]

Problemchild and Matty, both Very cool lookin' windshield ...... nice / sleek!

+1 I like both of them, too. I am a little more of a curved windshield fan, but I have never owned a boat that had one - :boggled:

[Greg Guimond]

Round "old style" versus more square "new style". I would need to see both underway at cruise :yes:

[mattyboy]

it is the same boat and that is not an older windshield or a newer one it is a custom one .

[Greg Guimond]

Custom? Who built it?

[mattyboy]

I have no idea ask problemchild it is his boat I just had pics of it from wayback

the older style classic windshield from the factory is like what Scott posted and was used on the early 16 18 and hornets


factory 18 windshield early classic 18

[CHACHI]

Looks like a bunch of old men trying to tie off that 18.

Ken

[mattyboy]

Ken
looks like they were having the old Canadian dock lines to American cleats problem but the guy in the baseball cap looks to have matters well in hand ;) ;)