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I hope you have some time to spend on this. If you can get into the frame of mind and stay calm it will go pretty smooth, and your blood pressure should be nearly the same as when you started.
I have done two complete window refits over the past 10 years. The first one was on our tug and can be seen here on the "projects" page:
http://sundowner.thebilge.com
The windows in the tug were from Diamond Seaglaze, a Canadian company. These were SUPERB quality and I paid dearly for it. You can check with them online by doing a google search for Diamond Seaglaze.
The windows in Seaweed are from Beclawat manufacturing also in Canada. They had me trace the bulkhead openings onto heavy paper and send them to them for templates. Here was the pricing estimate (are you sitting down?):
========================================= 2 Fixed shaped windows 17 / 20"w x 24" h, 6mm grey - $ 220.00 each 1 L/H, 1 R/H 2 Fixed 28"w x 17"h, 6mm clear temp - $ 175.00 each 2 Shaped Horz. sliders 53 / 59" w x 24" h 1 L/H, 1 R/H - $ 420.00 each F.O.B. Belleville, Ont. freight & brokerage extra - estimate $ 325.00
John McKenna Beclawat Manufacturing Inc. 613-966-5611 ext. 222 613-966-0878 fax ==========================================
I hope that the side of your pilothouse is flatter than mine was. The windows will bend up to about 1/8", but then the sliding starts binding. I made some shim pieces for mine on the outside underneath the flange and then filled with GE Silpruf 2000.
The Beclawat are not quite as nice as the Diamond Seaglaze, but they are still very good and better than the factory ones. Beclawat was not the easiest company in the world to work with, but again, still workable.
If I were to do anything again, I would have coughed up the money for an opening version of the window at the helm (hinged at top, opening out). You have probably seen the tilt-out versions of those. It was about $500-600. for *ONE* if I remember correctly - but still may have been worth it given all of the other stuff I was doing at the time.
Feel free to email me if you need anything else!
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