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/techn...e-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

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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-Sta...E: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-Sta...E: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 ...............