After a full year of sitting in pieces, the Bayliner 175 finally looks like a boat again. Following the restoration of the aluminum frames and the application of our metallic gray finish and UV-resistant clear coat, we have officially reinstalled the windshields.
This was a major milestone for the project. Installing a marine windshield requires a high degree of precision to ensure it’s both structurally sound and watertight. Here is the technical breakdown of the installation process and the hardware upgrades we made to prevent future corrosion.
The Investigation: Solving the Rust Problem
During the teardown, one of the most baffling things I discovered was the amount of rust on the original window hardware. For reasons I still can’t figure out, the previous owner (or the factory) had used non-marine grade fasteners.
- The Constraint: On a boat, especially in Florida’s salt air, anything that isn’t stainless steel is a liability.
- The Solution: We have committed to a total “Stainless Swap.” Every single screw, bolt, and washer being used to mount these windows is now 316-grade stainless steel. It’s more expensive, but it’s the only way to ensure we don’t have to do this again in three years.
The Project: Waterproofing and Mounting
- The Weather Stripping: To seal the frames to the deck, we sourced a dual-layer rubber weather stripping from Amazon. This provides two lines of defense against water intrusion.
- Alignment: We pre-cut the stripping to size and applied it directly to the boat’s mounting surface. This creates a gasket that prevents fiberglass-on-metal contact, which can lead to stress cracks over time.
- The Mounting: We started with six primary bolts to get the configuration right. Because we took these windows off a year ago, there was a bit of “persuasion” required to get the holes to line up perfectly with the fresh fiberglass.
- The Walkthrough Door: We added specialized weather stripping to the walkthrough window. This prevents the heavy frame from banging against our fresh metallic gray paint when the window is closed, acting as a buffer.
The Logistics: From a Hole to a Boat
If you’ve been following the series, you know this boat started as essentially a stripped-out hull. We’ve built the floor from scratch, handled the foam, the wiring, the painting, and the ski locker. Reinstalling the windows changes the entire profile of the vessel—it finally feels like we’re in the “home stretch” of the interior.
Final Thoughts and Next Steps
- Engine and Navigation: Now that the boat is sealed up, the priority shifts back to the engine accessories and the navigation systems. We’re pushing to get this thing on the water as soon as possible.
- The “Jack and Jill” Dynamic: This restoration has been a total team effort. Danielle’s precision with the taping and my mechanical work on the frames are what made this windshield look professional.
Watch the “unveiling” and installation here: Installed Our Window On The Boat
After a long day of sweating in the boat yard, we’re heading in for some dinner. Tonight’s menu is one of our favorites from www.dininginwithdanielle.com: Chicken Balsamic Pasta. We eat this at least once a week because it’s quick, fresh, and high-protein. If you need a solid post-project meal, that’s the one I recommend.
Y’all please take care.
Universal Self Adhesive Rubber Weatherstrip https://amzn.to/2Hq86h