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How to replace glass windows with polycarbonate sheet?

Are you planning on replacing the window glass yourself? Whether you’re replacing a wooden window or one with a plastic frame, follow our simple step by step instructions to make a success of this DIY project.

Requirements for a DIY window replacement:

Clear polycarbonate sheet 6.4mm - 12mm (your choice of thickness)

Glass tape 4 mm thick

Filler plates

Glazing glue

The material for making a DIY window replacement

In this DIY blog, we’ll take a new barn door without a window as our example so we don’t need to remove the glass slats. We’ll be using clear polycarbonate sheet (solid) to replace the window glass, and we can cut it to the exact size you need for free. If you want to cut the polycarbonate yourself, then we recommend going to our blog on how to cut polycarbonate sheets .

1: Remove the glass battens

To decide on the size of the window polycarbonate that you need to order, first remove the glass battens from the window that you want to replace. You need to measure the rebate size or the space in the frame without the glass battens. Remove the glass battens using a chisel or a screwdriver to pull them out.

2: Measure the window

Measure the window and subtract 2 mm all round. This is to allow for the polycarbonate expanding as the temperature rises.

3: Apply glass tape

Apply glass tape around the frame, 2 mm away from the edge. Then stick glazing tape on the back of the glass battens, once again 2 mm from the edge.

4: Position the window

Fill in the rebate with filler plates approximately 3 mm thick, also known as glass cubes. Next position the polycarbonate window in the frame.

5: Attach the window battens

Next, it’s time to attach the glass battens. Use a drill for this task.

6: Finishing the window

Give your polycarbonate window a neat, secure finish with glazing glue. Do this at both the front and the back of the window. Make sure that the glue is also applied between the windowpane and the glass battens. Clean your window using warm water and a few drops of plastic cleaner: your DIY window replacement is complete!

Order plexiglass for your DIY window replacement

Are you intending on replacing a window yourself soon? When you order window polycarbonate from us, we’ll cut the customized sheet for you free of charge and we’ll send your order as soon as possible.

Polycarbonate Polycarbonate Polycarbonate

Looking for more DIY inspiration?

View our blog for more fun and easy DIY projects. If you need any more information about replacing a window or about our products, please feel free to contact us.

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