Heat shaping and bending polycarbonate sheet to finish a searchlight. Lifeboat Conversion Ep54: [4K] 

I've not commented before but I am absolutely invested in this project. Cannot wait to see Alan out on the water

I watch a few other channels and often its "oops got the wrong size so waiting for another delivery"". That's why I love your solutions Alex, out there on the ice there is no next day delivery!

If you believe everything they tell you online Alan would never be build. Thanks for the video.

I like the remote searchlight idea, I did start work on a generic remote control 360 gimbal for mounting various things; spotlight,microphone,megaphone, laser rangefinder, LRAD, fluffy toy, whatever. But gave up as it was a lot of work/expense. Something for you to consider perhaps. Also. On the rare occasions when your are in warm climes, your solar cells will run inefficient, due to heat build up if there is no airgap between them and Alans hull.

I wish that you would give us at least a months notice when you will be working on the flood light box. I like to take off from work the day before, of and after in preparations for this event. I have to give notice to the droves of people that come to watch it on my large outdoor projector screen, whilst cheering you on every riveting step of the way. The extra heads up would allow for proper parking accommodations for the lines of cars and catering as well. Thanks in advance.

Long-time viewer, first time commentor. Excellent videos with great detail. Drain Holes are best fitted with a Split Pin to ensure that the Drain Hole remains open & functional.

Oh yes I do need a book for this winter. I don't like reading story books, I only read for knowledge. I'm sure a lot of people can relate to this. Steve

Quite enlightening.

i recommend reflective tape behind the searchlight

I really like your voice-over comments. I wonder if Alan is looking forward to the end with anticipation, or with some trepidation?

I really like you effort and perseverance.

OK done with the Oxford Union piece - congratz on that one :D

Maybe this is a stupid question. But what is the advantage of having a remote controlled mobile searchlight, vs having 2 or 3 fixed big lights that cover all the front of the boat?

A thought comes to mind as I watch you work on the searchlight cover. Fiddling with the cover while sitting high, dry and stable is one thing, but out at sea could be something quite different. Perhaps a short safety cord attached to the cover and the other end to the surface inside the housing would prevent losing the cover overboard. Consideration to keep the cord from tangling with the light's movement would be needed.

My only concern is heat build-up inside the enclosure... so, get thee to arctic conditions promptly!

Nicely done.

I have hardware and attachment method suggestions for you- I’ve done this sort of thing before! First, don’t feel too bad about getting a little scratch on the polycarb. While it is way easier to work with than you had heard, polycarb does scratch super easily. At work we say you can scratch the polycarb if it thinks you’re looking at it funny. Oh and don’t use windex on it, it will get cloudy. As for attachment. Have you considered rivet nuts? This seems like an ideal use, but I’m not sure about the compatibility with the fiberglass. Maybe a washer reinforcement on the inside would help the rivet not compress the fiberglass and pop though. I would probably combine it with a spade-headed or winged thumb screw if you can find it in ss316 where you are. You can buy all the different thumb screws from McMaster Carr, but they’re US only I think. Hope this helps- I’ve actually done this almost exact thing before - poly to fiberglass without interior access for holding the interior bolt. The solution at the time was to embed nuts in the fiberglass during the casting process, and honestly I wouldn’t recommend it as a solution. Over time it hasn’t held up the best and my project was a fairly stationary object indoors. I can see it delaminating from the stress of rocking on Alan. Rivet nut would be my top thing to try- especially if you have a friend with the tool. My last idea would be to do one last layer of resin and embed on metal tabs on the inside of the housing that you drill and tap after attaching, which would act as a washer and bolt all at the same time.

I did watch the Oxford Union video. That was very interesting. 10 out of 10 if anyone else is thinking of watching it.

Bring extra wingnuts ‘cus the currently fitted ones, will surely end up on the bottom of the ocean if rapairs will be needed, out on the water. 🙃

Its got a bit of a spidermans face to it. 🤣 great update 2x👍

Another option for a searchlight cover is a motorcycle windscreen. Different sizes and shapes. Find a fiberglass fairing to go with it from the breakers yard and modify as necessary to box in and mount. With a big enough windscreen and curvature, you could probably mount across an edge and not have to mount on a flat space.

Hello Alex. First comment for me here. First of All, Congrats ! Never been so excited for a not so much navigating boat (so far) videos. I love it all. About your angle problem for the bolts, what about tight hinge on top? If they are tight enough It will push on the joint just fine and allow the access at sea without fearing of droping the hatch in the water. Cheers !

Make longer videos. ~15 minutes seems to be a very popular length.

Very nice work. Does the search light put off any heat that needs venting?

A metal frame on top of the lens might help secure it and keep the gasket tight.

've occasionally witnessed other episodes before, loving the life-boat transformation - sometimes simplest solutions may serve best - why not merely fabricate a pressure plate, patterned to cover the top inch or so of the polycarbonate, with the 3 bolts going through it, thus their pressure will even out and firmly compress the transparent covering to the sealant/housing; the problem atop is more one of distribution of pressure, rater than of bolt-down force/torque; you may even bend/angle the top edge of this bolt-down metal plate - which would be essentially one big washer with 3 holes instead of one - so as to cover the upper edge of the plastic and when it (the metal) would reach the housing you'd be prevented from over-tightening those 3 bolts...

I'm about to try to bend PC to use it as a taillight cover that was broken. Needs to be bent to exact shape and then glued toghether. Maybe You have some tips You can share?

those little salad bowls, man.

I'm dubious about the holding power of the magnet mount after many miles of pounding waves.

would a 90 degree spring loaded latch clamp be any use for the front light access panel. but the shape of the housing maybe abit awkward.

Is it worth using a much longer rectangle of acrylic and bending it all the way over the light housing and down to the roof? This may add improved water proofing, added strength and provide a little insulation to the housing.

I see you are still using corded tools, will you be getting any cordless ones to keep on board just in case, or just a basic tool box?

Are you playing the guitar in the intro?

I don't know why you didn't make the housing into a slanted circle with a metal top that screws into aluminium blocks that are glued against the top side wall of the plastic housing.

It seems odd to me to have a searchlight that can only effectively swivel a few degrees. To look around at night, you'll need to rotate the whole boat. I must be missing something.

First I guess.

Shameless drone shot, shameless book plugs throughout and 100% overbuilt searchlight housing….. brilliant, my OCD can rest for several seconds. 👍