2 thoughts on “Guess we need to get those windows in before this thing turns into a birdhouse

  1. Hi Kyle,

    I have been slowly restoring a 1946 manor as well. I’m just about ready to install the observation windows, do you have any tips or recommendations that may help? Thx, rick

    1. Right on, Rick! I’ve over-engineered just about everything on mine since it’s for my professional use, so I used 1/4in Lexan. I would recommend you NOT do this lol – My weapons (including a reasonable powerful heat gun) were useless against it. A reasonable thickness should bend 100x easier, and it will bend cold. I predict you will fare much better than I if you have the original exterior trim. You can see in this post that mine was missing that on top and we had to fabricate an oak frame, which we were able to bend the curved sections into and held them in place with pipe clamps. We still almost destroyed the bottom trim from screwing it in against the resistance of the stuff. If you have those two things to work with, the trim and thinner polycarbonate, I think you’ll find that by simply making a cardboard template and having two people to bend the windows in after they’re cut (a jigsaw works fine) will not be nearly the challenge it was for us. Above all, do pay attention to my post where I attempt to take off the masking after like 2 years. That should have been a moment of joy, and I’m still meticulously scraping the stuff off with a heatgun and plastic scrapers. We thought keeping the masking on until we were further along would be a good idea since polycarbonate does scratch pretty easily. However, now I’m going to have to polish it all after I get the masking off, because the elements have bonded it to the Lexan tenaciously.

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