[C320-list] Leaking port replacements

[Jon Vez]

If you remove the port, yes the two pieces are inside and outside. However, you can do the horizontal gaps without removing the port and I would strongly recommend starting with those to see if your leaks get resolved. After getting two ports done, I realized this is where the leaks really were so I didn't remove the last two or replace the gaskets and no more leaks. It's easy to caulk the horizontal gaps with the ports in place--I filled the gaps from the inside and outside. I just squirted the gap from the inside until it started coming out from the front, taped that and squirted more from the outside.

For the Bomar tape, put the sticky side on the ports themselves and then press them onto the hull. If you do decide to remove the ports entirely, be careful not to overtighten the screws that are on the inside of the frame as the aluminum strips pretty easily (I know from experience).
I would do the gaskets as a last resort--This is the order I would follow, test after each step and if the leaks stop I would not go any further:

-O rings around the latches
-Rebed the horizontal gaps (with ports in place)
-Remove the entire portlight and rebed with Bomar hatch tape AND redo the gaskets. The reason I would do both of these steps is because it is much easier to replace the gaskets with the ports off the boat. 

I think I do have some pictures--if they aren't on the web site, I will post them shortly and let you know. I also may have some spare gaskets if you are interested. The new ports are a much better design and no longer use these gaskets so I have no need for them....

Regards,

Jon

-----Original Message-----
From: c320-list-bounces at lists.catalina320.com [mailto:c320-list-bounces at lists.catalina320.com] On Behalf Of hcreech at comcast.net
Sent: Tuesday, September 13, 2011 9:51 AM
To: C320-List at Catalina320.com
Subject: Re: [C320-list] Leaking port replacements

Jon, 
Yes some of this is confusing. When you remove the port 2 pieces, I am assuming one inside and one out, does the caulk go on the outside? I take from your comments you may not have changed the black rubber gaskets if you were to do this again? Does the Bomar tape, ring the outside part of the port? If so where is it in relationship to the new caulk? Shame there aren't pictures, I'll be sure to take some and share, but only if I do a good job. 

Herb 



----- Original Message -----
From: "Jon Vez" <jonvez at comcast.net> 
To: C320-List at Catalina320.com 
Sent: Tuesday, September 13, 2011 9:24:30 AM 
Subject: Re: [C320-list] Leaking port replacements 

Herb, 

It was only my saloon ports that leaked as well. I think that the UV does a real job of shrinking the caulking and as you say, with their angle they tend to be most exposed. 

I replaced 2 of the black gaskets until I realized that they weren't the problem. Those took me days to do because I was fairly obsessive about getting all of the old silicone out. I bought them from Defender. You just need to know what series the ports are. I believe ours are "1" for our vintage boat, but I can check if you don't have the info handy. 

I used black because my original was grey and I couldn't find that color. I also think the white gets very dirty looking rather quickly and I wanted to blend cosmetically. 
Yes, the same stuff you use for the V-Berth hatch (Bomar). If you rebed with the stuff, I strongly recommend you cut to size as the foam tape expands quite a bit and is a pain to clean up after they are in--let me know if you need more info or if any of this is confusing.... 

Good luck-- 

-----Original Message----- 
From: c320-list-bounces at lists.catalina320.com [mailto:c320-list-bounces at lists.catalina320.com] On Behalf Of hcreech at comcast.net 
Sent: Tuesday, September 13, 2011 8:58 AM 
To: C320-List at Catalina320.com 
Subject: Re: [C320-list] Leaking port replacements 

Jon, 
I am going to attempt to do mine as well, all the rain we had this year really found its way inside the boat. Interestingly the only ones that leak are in the saloon, I attribute this to the fact that they are not on a 90 degree angle like those in the aft cabin. A couple of questions, did you replace the black gaskets? If so where did you find them. By the "Bomar hatch tape," do you mean the same tape I purchased for the V-berth hatch that has adhesive tape on one side? Why did you use black 4200 rather than white? 

Thanks, 
Herb Creech 
Cloud Chaser 606 



----- Original Message ----- 
From: "Jon Vez" <jonvez at comcast.net> 
To: C320-List at Catalina320.com 
Sent: Tuesday, September 13, 2011 8:10:07 AM 
Subject: Re: [C320-list] Leaking port replacements 

Gary, 

I did this a couple of seasons ago. After pulling 2 ports to replace the 
gasket and rebed (If you go this route, I strongly recommend the Bomar Hatch 
tape), I realized that the bedding was not the problem, so I tried rebedding 
just the horizontal gaps on the rest--and that stopped the leaking. Didn't 
even need to replace the gaskets. Once I got the hang of it, it took me 
about 20 minutes per port to just the gaps. I did these with the ports in 
place. 
I used Black 3M 4200 and a small West Systems Syringe to get the 4200 in 
each gap. I peeled out the old stuff with a dental pick and tried my best to 
clean out any residue with denatured alcohol, taped both sides around the 
edges and filled the gaps. I then used a small putty knife to smooth out the 
caulk and make sure the gaps were totally filled. Looked professional and 
really worked. It was actually quite easy to do. 
To me, the most difficult thing to do with these ports is replace the 
gaskets--it takes a lot to get all of the old silicone out of the small 
channels and get the new ones in....hope this helps and if you have 
additional questions, please ask.... 

Regards, 
Jon Vez 
Formerly #582 

-----Original Message----- 
From: c320-list-bounces at lists.catalina320.com 
[mailto:c320-list-bounces at lists.catalina320.com] On Behalf Of Gary Magnuson 
Sent: Monday, September 12, 2011 9:37 PM 
To: C320-List at Catalina320.com 
Subject: Re: [C320-list] Leaking port replacements 

John, 
I have been going back over the various posts covering the leaky port 
issues, and am ready to tackle the job. I have replaced the O rings, but 
still get some dripping when ever it rains. Some comments have suggested to 
just reseal the small gap between the frame halves. Can you describe your 
process and about how long it took per window? My 1995 has 7 windows, 
including the 4 in the main salon. If I get started with this project, I 
plan to do them all at the same time. A local Catalina broker rep suggested 

taping the hull around the frames before removing the frames to limit the 
amount of clean up. Unfortunately, he is now in the Hospital and 
unavailable for additional questions. 

Thanks, 
Gary Magnuson 
1995#205 
----- Original Message ----- 
From: "JJ Morrison" <sail-ability at sympatico.ca> 
To: "Catalina List" <c320-list at catalina320.com> 
Sent: Wednesday, September 07, 2011 6:27 PM 
Subject: Re: [C320-list] Leaking port replacements 



Herb; 
Have you tried replacing the gasket between the two halves of the frame on 
the outside of the portlights? All four of mine were leaking and I doug out 
and replaced the original gasket with 3M 4200, now nary a drop leaks. 
Cheers 
JohnM 
1999#574 

> Date: Wed, 7 Sep 2011 21:47:59 +0000 
> From: hcreech at comcast.net 
> To: C320-List at Catalina320.com 
> Subject: [C320-list] Leaking port replacements 
> 
> Dear List, 
> 
> All of my opening ports now leak despite my efforts that worked it the 
> past. Rather than rebuilding them I was interested to see if anyone on the 

> list had actually replaced them with a third part port other than Lewmar. 
> I plan on looking at the up coming sailboat show but wanted some advance 
> information if possible. 
> 
> Thanks, 
> Herb Creech 
> Cloud Chaser,606 
> 
> 
> 
=