Re: Portlight Install
It can be done. But it is also very messy work, if you have a weekend that you can spend devoted to this project then go for it! If not it is best to leave it to the pro's.<br /><br /> But here is how! The first thing you need to do is make some templates, if you plan to install two on each side you will need eight. Figure out were you plan to mount the portlights and tack up the templates on the outside and INSIDE the cuddy cabin. Make sure that it both looks good inside and out, AND that it does not take away from the structural integrity of the hull.<br /><br /> Once you have figured out were to mount them, outline the cut-out opening and trace it with a black sharpie. Drill hole on the line with a large bit so that the blade of the saw can fit through it. SLOWLY cut out the portlights opening. Once the opening is cut out dry fit the portlight and the backing plate, sometimes the backing plate will not be flush and you will have to make a make a plywood shim that allows you portlight to mount flush with the inside of the hull. Once you are done making the shim epoxy it to the inside of the hull. <br /><br /> Finally dry fit all your portlights and mark where you have to drill the holes for the bolts or screws. Drill out the holes and dry fit the portlights one last time, but this time bolt them to the hull to check that everything lines up correctly.<br /><br /> Now is time to get out the 5200 or which ever sealant you plan to use, BUT first with every portlight removed you will need to sand around the cut-out hole to remove any wax, then you will need to clean each portlight to remove any dust or oils. Use painters tape to cover anything you don't want sealant to get on and wear some old clothes. <br /><br />Here comes the fun part, you now need to apply sealant to the port lights flange and smear some sealant around the opening in the hull. Slowly push the portlight against the hull and have a partner insert the bolts into holes. DO NOT fully tighten the bolts yet, Only tighten them 85%, you want to wait 24 hours then come back and tighten them all the way.<br /> <br /> Now you are done installing the portlights, all you have to do now is remove the painters tape (use a box cutter to trim the sealant) and you will be done. If you want to know more about boat repair, go to a local book store and buy the "Good Old Boat" by Don Casey.
<br /><br />Picture of portlight I want to install<br /><br />
