[C320-list] Portlight Replacement/Repair?

[David Wellerstein]

Thank you Christian (and others).  I’m thinking that with the crazing I should probably just replace them.  But I may take a stab at the G gasket.

In any case, this is about the best and closest article/post I’ve found on the replacement:  https://mysailingfix.com/2017/11/15/portlight-replacement/ <https://mysailingfix.com/2017/11/15/portlight-replacement/>

If anyone has others, or better yet a video, to share, I’m all ears and eyes.  But I think I’m going to bite the bullet and buy four of the new portlights for the cabin and give it a go.  Worst case I have to have someone come out and do them.  I’ll still be able to use the windows.

Thank you and happy sailing!  Looks like it will be a nice day on the Bay tomorrow!

—David

David Wellerstein | dwellers at mac.com | 925.301.6581 (m)

> On Mar 25, 2022, at 8:52 AM, Christian <ccaper at gmail.com> wrote:
> 
> David,
> the source of your leak is likely the "G" gasket.  When I got my 320 6
> years ago, every portlight leaked, and leaked badly.  I replaced all the
> rubber gaskets.  Yes, they are a real PITA to replace.  All still leaked.
> I then replace the O rings in all the dog ears.  All still leaked.  I then
> read about the G gasket on our list, looked closely at mine, and yup, dry
> rotted.  Given your hull number, I'd guess yours are dry rotted too.
> 
> I had perfect success with fixing without rebedding the hatch.
> 
> On each portlight, horizontal, mid section, visible on the outside (deck
> side) of the hatch, is a seam, filled with a gray gasket.  I would guess if
> you inspect closely, you'll find that dry rotted.  What I did is take thin
> needle nose plier, and a pick, and pulled that seam portion of the gasket
> out (this is the g gasket, if you are able to extract a whole portion out
> without tearing, you'll see why it's called a g gasket).  It should come
> out fairly easily, with minimal need for cleaning the surface afterwards.
> 
> Then, after you've removed the g gasket, on the outside (deskside) cleanly
> take off the aluminum along that seam, and where it meets your fiberglass.
> 
> Then, with this Dow Corning sealant:
> https://www.catalinadirect.com/shop-by-boat/catalina-350/hatches-ports/replacement-parts/sealant-for-hatches-amp-plex-fixed-ports-black/
> 
> From the outside thickly fill in gap.  Then, with the back of a spoon,
> smooth the sealant flat (why you need the tape off your frame and
> fiberglass).  Then, apply another squirt on the inside of the frame (this
> is a little harder to reach with the sealant nozzle, and unfortunately
> harder if you have your rubber gasket for the lens in, but can be done;
> fortunately on the inside, doesn't have to be as clean, it's hidden well).
> Let cure.  Come back with a razor blade, very lightly score the sealant
> along your taped area, and then remove the tape and the excess sealant on
> the tape should cleanly break.
> 
> I have not had one single drop leak since I did this.  It was the source of
> ALL my leaks.  And this is actually easier to do than replacing that rubber
> lens gasket.  I did all 7 of my portlights in about 4 hours.  Don't cheat
> and get another sealant.  You want that Dow Coring sealant I recommended.
> Its used to hold windows in skyscrapers.  It's the real deal, works great,
> bonds well, and breaks along light scoring for a nice clean up.  You could
> never tell I did the job it was so clean (except for my first frame where I
> hadn't taped, and then realized I needed to tape for this sealant).
> 
> Hope this helps, happy to answer any questions.
> 
> -Christian Caperton 1994 C320 #138 "Canuck" Monroe Harbor, Chicago, IL
> 
> On Thu, Mar 24, 2022 at 9:23 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
>> 
>> 
>>