diy screens

One of the “features” of buying a 31yo sailboat is that all the portlight screens have gone somewhere, other than on the boat.

We have 14 portlights aka as windows that open. Mach 5 had one screen that was bent and ripped — if it could talk, that screen and frame would have a story to tell!

I tried buying an aftermarket screen–no bueno. I called around trying to find someone who still made the screens for our boats. No dice there. Searched Pinterest and YouTube for other DIY screens. Found one idea that used foamboard–which looked like a great idea–except Mach 5’s portlights don’t have a lip or edge to insert the frames into. Mach 5 needed frames that could attach with screws, spacers, and washers to stay in place.

What did we do?

I mocked up a frame with paper towels. Then Mark took the paper towel prototype and had TAP Plastics make actual frames from–you guessed it, plastic!

For screen material, I bought No-See-Um screen material.

Stretching and gluing the screen material on the frame is a four-handed job! I would hold down the fabric on the frame while Mark added E6000 and spread it around the frame. There is E6000 on the frame, then a layer of fabric, and then another layer of E6000.

Each frame was about $10, plus a smidge of screen material that cost a total of $20, and the screws, spacers, and washers. Each frame was less than $15.

We are pleased (so far) with our screens. It’s been wonderful to not have so many bugs in the boat! Next up, I need to make a screen for the companionway.