[C320-list] Portlight Replacement/Repair?

[P.F. Ross]

Hi David,

You will find much discussion on the list on the portlight topic.  I putzed
around with mine for many years and was never able to get them to seal to
my satisfaction, even though there are others who have had better luck.
And you are right, trying to replace the rubber seals in them is nigh on
impossible.

Two or three years ago, I replaced all of my opening portlights with the
newer design Lewmar Standard Rectangular Size 1 from Defender (their p/n
900365-1-WHI).  At the time, the Defender 1st price was just under $200
each and I broke it up into two projects, doing the aft stateroom first and
the main salon later.  Helped with cash flow as well as project load.

These are a much improved design with only one frame seam (at mid bottom)
and no through holes in the lens for either hinges or closures.  Absolutely
stopped all portlight leaks (although make sure you get them bedded
properly, I used Bed-It butyl tape).  The original design had several
possible leak paths.

Replacing the portlights yourself is not difficult, just a little tedious
to make sure you get all old sealant removed and cleaned for the new
lights.  I used a plastic putty knife and mineral spirits, IIRC.

I have not replaced my fixed portlights, although I did rebed the one in
the aft stateroom.

Good luck, you can do it!

Frank Ross
Beta Wave #206
Naples, FL

On Thu, Mar 24, 2022 at 10:23 PM David Wellerstein <dwellers at mac.com> wrote:

> I’ll put this out to the list…
>
> We had several heavy rains this year and our ’94’s port lights almost all
> leaked, some quite badly.  Even to the point where I avoid getting spray on
> them when I hose the boat down.  They are quite crazed (as am I) too.
>
> We bought new rubber gaskets but they are an absolute B to put in and I’m
> not sure that’s the source of the trouble anyway.  I think the deck hatches
> are ok though I did need to re-affix the head hatch glass to the trim.
> That seems to be holding.
>
> Has anyone done a full port light replacement?  Order of magnitude cost?
> They appear to be about $240 apiece from Catalina Direct so my simple math
> says that’s about $1700 for the ports.  Replacing them myself looks very
> involved, tedious and time consuming.  Is this something a general yard can
> do or are there specialists out there?  It appears the non-opening windows
> are watertight but should they be replaced as well?
>
> Thanks as always!
>
> David
> C320 #118 Dream Catcher
>
>
>