epoxy portlight frames?

[mitiempo]

hello all
I am in the middle of a refit of a CS27. The original portlights are installed with thin aluminum frames screwed through the cabin sides, sandwiching the plexi against the cabin side. The plexi is thin enough to flex when I push it with my finger. Obviously I will change to thicker plexi, probably 1/4" or so, but not too thick as there is a slight curve to the cabin side. There are six, three per side and I have this idea of moulding the frames out of epoxy and biax or similar. My plans are to make a mold (all six are thankfully the same size), probably about an inch in contact with the cabin side and 3/4" overlapping the plexi. I plan to bolt them through the cabin sides with sealant, the overlap holding the plexi in place with no holes drilled through it at all (allowing for expansion of plexi of course). I will finish the frames white to match the deck and cabin colour. The cabin side is solid glass about 1/4" or 5/16 " thick. I think that the frame should be 1/2" to 5/8" thick where it bolts to the cabin side and about half that thickness where it overlaps the plexi. I seem to remember seeing this done on a blog I can no longer find, although as I remember there were not many details. Anyone have any ideas or criticisms of this?

[David]

I've seen it on a blog as well. The frames turned out very nice.

[Rachel]

I think I saw it in reference to an Allied boat - maybe a Seabreeze?

Oh, here it is:

http://www.westsystem.com/ss/new-window ... -stardust/

[mitiempo]

thanks rachel
I'll post results when finished, but it's only one of many projects that are ongoing.