DIY Polycarbonate Hurricane Panels

Polycarbonate hurricane panels are a cost-effective and reliable way to protect your home from the destructive forces of hurricanes. These panels, made from a durable plastic material, are designed to withstand high winds and flying debris. In this guide, we’ll walk you through the process of creating your own DIY polycarbonate hurricane panels.

Understanding Polycarbonate

Polycarbonate is a type of plastic that is incredibly durable and resistant to impact. It’s often used in applications where safety and durability are paramount, such as bulletproof windows and eyewear. This makes it an excellent material for hurricane panels.

Polycarbonate is also lightweight and easy to work with, making it a popular choice for DIY projects. It’s transparent, allowing for natural light to come in while still providing protection. It’s also UV resistant, which means it won’t yellow or degrade in the sun.

Materials and Tools Required

Before you start your project, you’ll need to gather the necessary materials and tools. Here’s what you’ll need:

  • Polycarbonate sheets
  • Measuring tape
  • Marker
  • Circular saw
  • Drill
  • Screws
  • Washers

When selecting your polycarbonate sheets, make sure they are at least 0.093 inches thick. This thickness will provide adequate protection against hurricane-force winds and flying debris.

Measuring and Cutting the Panels

The first step in creating your DIY polycarbonate hurricane panels is to measure and cut the panels to fit your windows. Use your measuring tape to measure the height and width of your windows, and then mark these measurements on your polycarbonate sheets with a marker.

Next, use your circular saw to cut the panels to size. Remember to always wear safety glasses when cutting polycarbonate, as small pieces can fly off during the cutting process.

Drilling and Installing the Panels

Once your panels are cut to size, you’ll need to drill holes for the screws. Measure and mark where you want your screws to go, ensuring they are evenly spaced and not too close to the edges of the panels.

Use your drill to create the holes, and then align the panels with your windows. Secure the panels in place with screws and washers. The washers will help distribute the pressure and prevent the screws from cracking the polycarbonate.

Maintaining Your Polycarbonate Hurricane Panels

Polycarbonate is a durable material, but it still requires some maintenance to keep it in good condition. Regularly clean your panels with a mild detergent and warm water to remove any dirt or debris. Avoid using abrasive cleaners or brushes, as these can scratch the surface of the polycarbonate.

Inspect your panels regularly for any signs of damage or wear. If you notice any cracks or chips, replace the panel as soon as possible. Although polycarbonate is highly resistant to impact, it can still be damaged by severe weather conditions or prolonged exposure to the sun.


DIY polycarbonate hurricane panels are an effective and affordable way to protect your home during hurricane season. With the right materials and tools, you can create your own panels and install them on your windows. Remember to always follow safety guidelines when working with tools and to regularly maintain your panels to ensure they remain in good condition.

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