[C320-list] Interior Port-light trim ring

[Dave Cushman]

I replaced the four main cabin Lewmar ports with the new style Lewmar 
ports. The old ones came out easily and the new ones fit perfectly into 
the existing holes with no modifications whatsoever. It took two people 
for the new installation,  one to just provided some pressure on the 
outside and keep them positioned while I inserted the screws and 
tightened them up. I used a battery drill with a Phillips bit and 
torqued them as if I were putting on a new tire (opposite sides slowly 
moving around the ring.)  I inspected the edges of the fiberglass holes 
and they were perfectly sealed so no rain water at all ever got into the 
deck laminate. It looked as good as the day the boat was manufactured.  
The ones aft were not leaking at all, so I figure I can do that later 
on. Perhaps I was a bit misleading about the portlight replacement time. 
I removed the old ports and  replaced the four ports in well under two 
hours but I did not count the time taken to cut the trim rings. This 
takes more time, but they can be done at home once you mark and identify 
the shape. The critical  time that the window is open to the elements is 
what I reflected in the 2 hour item. And the trim rings are decorative, 
the windows function fine without the trim rings. So you can take your 
time with them. As for the Dremel tool, it is ideal  for cutting. It 
looks like Catalina used a shear to do the original install, but my tin 
snips were challenged with the curves.

As for butyl tape, a definite must use. It is easy to work with. I would 
not consider silicone. That being said you need to do this on a warm 
enough day so that when you tighten the screws the butyl tape seats 
properly. If it is too cold it will not work properly.

I followed the recommendations of the Mainsheet article and used the 
existing screw fasteners from the old ports in the new Lewmar windows. 
It is important that when you take the old ones out you identify the 
sequence and put the same ones back in the corresponding hole in the new 
ring, otherwise you will have issues with the varying thickness of the 
fiberglass. The screws were all the right length and I did not have to 
cut anything.

Dave Cushman

It Tips, #631