As others might benefit, I thought I would add a final note to this thread to report on the outcome.
Our pal was able to obtain made to order replacement windows of 1/4" plexiglass locally without difficulty. The greatest problem proved to be the "sex-bolts". These were available through BeneteauUSA for $.50 USD each several years ago but are no longer available except by special order at several dollars each. After dismounting his windows--since both sides had to be replaced to match, he needed upwards of 60 bolts due to corrosion
, frozen bolts et al.
The solution proved to be 3M VHB 5962 double-stick tape which is also used to secure the canopies on several types of aircraft. This is applied directly to the plexiglass and to the coachroof sides with a primer applied to the gelcoat
. The grip is tenacious and cannot be adjusted once the tape makes contact with the glass or coachroof sides so alignment guides have to be set-up in advance and everything dry-fit.
That's it. VNB only. Some may question the adaquacy of this installation
but the yacht is now at the Ocean World Marina in the Dominican Republic
, having made the trip from Tampa in a few weeks, essentially all to weather
, in some very trying conditions that reportedly had the entire top-sides submerged in waves several times. Only one small leak at a point less than an inch long where our pal admitted he skimped on the primer because he was "in a hurry". Fortunately, that was corrected with an injection of compatable caulking--also by 3M (obtained for just such a contingency). Their next stop will be on the south coast of Puerto Rico
In hind sight, our pal's only comment was that he wished he'd used 3/8" glass rather that the 1/4" that matched the original so that the edges of the glass could have been beveled more.