BWY window holes not lining up

[Clipster]

I purchased a full set of windows for my 2000 X, and while the side windows are fine, the forward windows are not. Only 4 of the 6 holes line up for each window.

In the included instructions BWY suggests drilling a larger hole in the cabin in this case, but that sounds super sketchy to me. If the surface was flat I'd probably forgo the bottom two bolts and just rely on the sealant, but since the surface is curved the windows need to be bent in order to seal correctly.

Has anyone else encountered this problem? If so, how did you solve it?

[Russ]

I would call BWY and explain. They might have the best answer.

[trswem]

I just replaced my windows. I had a number of holes not line up as well. Redrilling went easy though and I got a good result.

[jordans1984]

I made my own windows from acrylic plexiglass off amazon after the windows from BWY being too small and completely different than mine, which is a MAC21 not a V-21. I had great luck using dish-soap to get a smooth drill hole and edge cut from a bandsaw. Just go slow and use a sharp drill bit, hopefully with a drill press.
BWY did accept the return but I had to cover shipping. It still cost me less in the long run and now I have plexiglass skills!

[Herschel]

Question: I'm looking at a possible leak at my forward starboard window ('98 26X). I haven't popped out the plastic plugs, yet, to see how they are attached. What will I find when i do? A previous thread about leaks said it took two people to tighten window bolts. One on the outside with a screw driver and one below to tighten the nut. Does that sound right? I can't imagine where the top of the bolt would be. I can't see anything on the cabin top deck around the windows.

[OverEasy]

Hi Herschel!

On our 2001 Mac26X the exterior holes are actually in the plexiglass as black countersunk Phillips head screws (aka: bolts for the technical purists ) with the nuts on the interior with this funny white capture caps sets.

Haven’t yet replaced ours on Over Easy but the internal plexiglass UV crazing tells us we’re long since due… especially the aft side windows after 23+ years in the elements. On the list of “To-Do” projects for 2025.

If anyone is drilling plexiglass then Jordans1984 is absolutely correct on having very sharp drill bits and saw blades!!! That and going SLOW with bar soap as lubricant. I’ve done general aviation windscreens for small planes in the past. They are blown formed and come without any holes as one has to match drill to the sheet metal aircraft structure (every aircraft is sorta unique to themselves in this regard as are the windscreen pieces… so gently gently is the key to avoiding making expensive scrap!)

Best Regards,
Over Easy

[trswem]

There are plexiglass specific blades for jigsaws also. I've had very good results setting my speed to the lowest setting.

[Herschel]

Hi Herschel!

On our 2001 Mac26X the exterior holes are actually in the plexiglass as black countersunk Phillips head screws (aka: bolts for the technical purists ) with the nuts on the interior with this funny white capture caps sets.

Haven’t yet replaced ours on Over Easy but the internal plexiglass UV crazing tells us we’re long since due… especially the aft side windows after 23+ years in the elements. On the list of “To-Do” projects for 2025.

If anyone is drilling plexiglass then Jordans1984 is absolutely correct on having very sharp drill bits and saw blades!!! That and going SLOW with bar soap as lubricant. I’ve done general aviation windscreens for small planes in the past. They are blown formed and come without any holes as one has to match drill to the sheet metal aircraft structure (every aircraft is sorta unique to themselves in this regard as are the windscreen pieces… so gently gently is the key to avoiding making expensive scrap!)

Best Regards,
Over Easy

Thanks. I'll take a look the next time I go up to the boat. Never noticed them.