The Boat Guy: Protecting Your Plastic Windows From Damage And Fading –Part 2 – Making Covers
marking details
August 27, 2026
By Marc Robic
Part 1 of this series can be found here
The best way to give windows the longest possible life span, is to actually cover them up. That is exactly what I did and it only took me a day to design, create a pattern and have a perfectly fitting cover made.
It’s an easy process that will save you time and money. You will not have to find and wait for a canvas shop to come and take measurements, etc. Once you have your pattern made, you will also have the option of purchasing your own Sunbrella fabric and find a local shop or or needlework shop to sew your cover.
Here’s how: You will need a number of large format craft cardboard sheets, purchased at any craft and hobby store (I got mine at my local dollar store), a roll of masking tape, scissors and a Sharpie.
Starting on the front window, a little past the center, use masking tape to apply and hold the cardboard in place. With the Sharpie, identify the center line from top to bottom. Tape the next cardboard to that first piece and, as you turn the corner, make folds in the cardboard to shape it in place. Cut any excess. Keep repeating until you’ve covered and shaped the entire side of the dodger. Use smaller more manageable pieces wherever necessary.
Once you have it all done and shaped, mark where you want the attachment points and what kind. In my case, on the side, I used the handholds. Using pieces of cardboard, I made what will be two wraparound strips of Sunbrella and Velcro straps. On the lower side corner, I identified where I want bronze or brass eyelets to be added where a bungee cord and plastic hook will be used to stretch and secure the cover.
On the top front window, I marked where the exiting snaps are where I secure the window when rolled up. Snaps will be added to secure the cover on the same snaps. Using the traveller rail, I again used pieces of cardboard to make what will be a wraparound strip of Sunbrella and Velcro straps.
With the pattern now in hand, I brought it to my local canvas maker and selected the Sunbrella fabric and color. Using the cardboard pattern, he made the cover using a single large piece of Sunbrella. Adding the attachment strips of Sunbrella and Velcro. Once the Sunbrella cover and attachment strips were completed, we test fitted it and selected where to add the bronze eyelets.
By doing all the upfront work, you not only save time and money, but you will be certain it is exactly how you want it to be.
I used the service of a canvas maker, but you can easily find a local alteration shop that has a commercial grade sewing machine. Purchase your Sunbrella fabric at a large fabric store. Just make sure you buy enough to sew a seam on the outer edges, which need about an inch past all the edges of your finished pattern. IMPORTANT: Purchase colour coded outdoor UV resistant thread and a roll of Velcro at the same time.
One final piece of advice, once you have the pattern completed and still on your dodger, take a few pictures to show the sewing folks what it is and will look like. As they say, a picture is worth a thousand words.
Please note that I only made a pattern for half the dodger. Since both sides are identical, once marked on the Sunbrella fabric, the pattern I made for the starboard side, was simply flipped over on the fabric to mark the port side.
After two years now, I can tell you it has definitely helped protect the plastic windows from sun and bird poop and, what’s even better, is that it truly an easy and low cost semi-DIY project.
Marc Robic – The Boat Guy – Marc is a member of BoatCan who, with his wife, sails their Catalina 270, Aquaholic 3, out of the Ile-Perrot Yacht Club in Montreal, where Marc spent 16 years as Harbour Master. They are also regular Caribbean bareboat yacht charterers.
With over 40-years experience on boats, Marc is our OnBoard do-it-yourselfer.
