The polyvinyl chloride material that is most popular for windows (there are alternatives but they are either very expensive or rather inflexible or both), is not as resistant to sunlight as sailcloth and canvas. As a result, it is usually necessary to replace it two or three times during the life of a sail or a dodger. This is not a job to be feared. It is actually rather easy. There are, however, some tips that we can pass along that will make the finished job look just as good as the work of a professional.

First, be very careful to install the new window with the surrounding fabric flat and relaxed. If there is any bias stretch in the material, there will be a tendency for the new window to have diagonal wrinkles. The best way to ensure that this does not happen is to remove the old window only after sewing the new one in place. That old window, unless it is so far gone that it has actually split, will keep the panel from stretching on the diagonal. To accomplish this, it will be necessary to make the new window one-half inch or so bigger all the way round than the old one.

If the old window is torn or split or if there is no excess material to allow for a larger window, the old one will have to be removed to allow for the new one. This can be done, but be very careful when lining up the new window to position it on a flat and relaxed panel. We like to use push-pins to hold the fabric down on a plywood board. That way it can be held in place until the new window is basted in place.

This basting is very important. The acrylic basting tape should be used all round the new window. In addition it is a good idea to staple the window at intervals of a foot or so if possible. Without the basting it is almost impossible to sew the window in place without it skewing at some point and creating an ugly bubble as the circle of sewing round it is completed. A walking foot sewing machine, of course, makes basting less important but it is still a good idea. When using a regular machine, the skewing problem will be reduced if the window material is underneath as it is sewn. This ensures that the feed mechanism on the machine will be pulling directly on the "sticky" plastic rather than attempting to pull it under the sled of the presser foot. The edge of the window can be felt through the fabric to guide in the placement of stitches (that edge will not be visable). If for some reason the plastic must be up as it is sewn, baby powder can be sprinkled over the surface to make it slide along more evenly.

When sewing round a window it is a good idea to break the task up. That is, don't sew all the way round it in one pass. Rather sew down one side at a time and try to sew parallel sides consecutively. For example, roll a dodger panel up from one edge and sew all along the closest window side. Finish that stitch with a short reverse at the beginning and end. Then continue rolling the panel to the other parallel window side and sew it. Pull the panel out from under the machine and roll it the other way sewing the last two parallel sides. This technique makes it easier to keep the window from breaking loose from its basted position.

The window edges can be trimmed out in any number of ways. We will describe one technique that we like to use here. It is not necessary to "dress" the raw edge of the vinyl material so it can be left uncovered. This edge will usually be on the inside surface of a dodger so its appearance is also not critical. The fabric side of the window edge, however, needs to be finished. That edge can be rolled under and sewn if there is sufficient cloth (use the basting tape to hold the rolled edge in place). But there is often not much extra cloth for such an edge in a window replacement. In these cases we like to place a three-quarter inch binding tape flat on the rim of the window. It can be basted in place and sewn with two rows of stitches. Binding tape comes with two prefolded edges so it provides a nice finished appearance with very little work.

If you have an old vinyl PVC dodger window that needs to be replaced then you owe it to yourself to check out the streaming online video which gives you step by step instructions. Search on part number 102621.