When the pandemic forced restaurants and breweries to rethink how they served customers, outdoor seating quickly became essential. In Seattle’s Columbia City neighborhood, Flying Lion Brewing saw an opportunity to make a lasting change rather than a temporary fix.
Co-owner Griffin Williams and his family-owned team wanted to create an outdoor Streatery space that truly reflected the spirit of the brewery: inviting, practical, and community-centered. The goal was to turn a small, dark exterior into a bright and comfortable patio that could be enjoyed throughout the year.
Recently, The Polycarbonate Store team visited Flying Lion Brewing to see the finished patio enclosure in person and talk with Griffin about how the project came together. What began as a response to pandemic restrictions has evolved into one of the most eye-catching and welcoming features of the brewery.
Why Flying Lion Brewing Chose Polycarbonate Sheets
Like many local businesses, Flying Lion first relied on a simple tent setup to get through the early months of the pandemic. It was functional, but far from ideal. As restrictions lifted, the team wanted something more permanent that would feel like part of the building rather than an afterthought.
Before construction began, Griffin explored several possible materials. He learned the hard way that hardware store corrugated PVC wasn’t going to hold up to his conditions. Solid walls offered privacy but blocked too much light, making the space feel closed in. Solid-vinyl panels seemed too temporary and less durable for long-term use. After weighing the options, he landed on multiwall polycarbonate sheets as the best combination of strength, insulation, and light transmission.
“We really wanted to make it comfortable after watching people during the pandemic sit outside, bundled up in their sweaters and coats, just drinking a beer when it’s 40 degrees out,” Griffin said during our visit.
Working with his expert, Meredith from Polycarbonate Store, Griffin received expert guidance on what products would work best for his goals. “I had no idea what we were doing,” he admitted. “I had no idea how to attach it to anything or how to seal it. They got us the right accessories and the right hardware and some recommendations for the installation to go along with it.”
After careful consideration, the team selected 25mm triple-wall polycarbonate for the roof and lower wall panels. The thicker triple-wall material provided the insulation they needed to retain warmth while still allowing plenty of light into the space. For a north-facing patio that naturally gets less direct sunlight, the clear panels made a noticeable difference.
“I really wanted it to be as clear as possible, letting in as much light as possible,” Griffin said. “We have a really dark space, so anything we can do to make it more open to light is better.”
What the Brewery Learned from the Build
Like most hands-on projects, the patio build came with a few lessons learned. One of Griffin’s biggest takeaways was the importance of doing things right the first time.
“At the end of the day, it makes sense to build it the right way and insulate it the first time,” he said. “Don’t install the wrong roof and then uninstall it and then put the right roofing on. It’s a lot simpler to do it right the first time.”
The team also experimented with a few ideas along the way. Hoping to make the wall seams nearly invisible, they tried using a clear solvent cement similar to what is used for PVC pipe. Unfortunately, the method clouded the panels instead of blending them seamlessly.
“We were trying to have it be as seamless as possible,” Griffin said. “But it just clouded up the plastic, and it doesn’t look that good.”
It was a useful reminder that polycarbonate performs best when paired with the right accessories. Using proper joiners, sealants, and hardware designed for the material ensures a cleaner finish and a much smoother installation experience. Avoid using solvents or adhesives that are not recommended for polycarbonate, as they can damage the panels and may void your warranty. When in doubt, check with your polycarbonate expert before applying any third-party products to your panels.
“Get the right accessories,” he said. “It’s worth it to make your job easier.”
How the Polycarbonate Patio Performs Over Time
Now, nearly three years after installation, Flying Lion’s patio enclosure still looks as good as the day it was built. The panels have not yellowed or lost their clarity, and the structure continues to perform through Seattle’s changing seasons.
“It’s been great,” Griffin shared. “Everything still looks brand new. Everything is still clear. It’s not yellowed. It’s holding up great. It’s keeping the cold air out and the warm air in.”
Durability has been one of the biggest surprises of all. “I’ve been really happy with the product,” he said. “It’s easy to use and easy to work with. Really durable. It’s just really bomb proof.”
The finished patio now feels like a natural extension of the brewery’s cozy, community atmosphere. The polycarbonate sheets form a sloped roof and the lower half of the enclosure walls, creating a comfortable and well-lit space for guests. On the entrance wall, a custom light-up sign spans the full width of the patio, greeting visitors with the brewery name as they enter. The sign glows through the additional polycarbonate panels in shifting colors, adding a warm, welcoming touch that makes the space stand out.
The result is a space that feels both functional and beautiful, bright on cloudy days and warm on cool nights. What started as a pandemic workaround has become a permanent, year-round gathering place for neighbors and friends to enjoy good beer and good company.
Project Materials Used
Flying Lion Brewing used a combination of triple-wall polycarbonate sheets, extrusions, and sealants from Polycarbonate Store to build their patio enclosure and custom light-up sign. The materials were selected for their strength, insulation value, and clarity, helping keep the space warm, bright, and durable through Seattle’s diverse seasons.
Roof Materials List:
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25mm Triple-Wall Polycarbonate Sheet, 4x10 Clear (5 qty)
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Polycarbonate End Cap (U Channel), 25mm x 4 ft (5 qty)
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Foam Glazing Tape, 3/8" W (1 qty)
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Vented Polycarbonate Tape, 2" W (1 qty)
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Sikasil-N Plus Silicone Sealant (1 qty)
Sidewalls and Light-Up Sign Materials List:
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25mm Triple-Wall Polycarbonate Sheet, 4x8 Clear (7 qty)
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Polycarbonate End Cap (U Channel), 25mm x 8 ft (7 qty)
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16mm Triple-Wall Polycarbonate Sheet, 4x8 Clear (1 qty)
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Foam Glazing Tape, 3/8" W (1 qty)
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Vented Polycarbonate Tape, 2" W (1 qty)
Thinking about your own outdoor build?
Whether you are enclosing a patio, coving a walkway, building a pergola roof, or adding weather protection for your business, our team can help you choose the right polycarbonate sheets and accessories to bring your project to life. Explore Polycarbonate Sheets