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post #2 of Old 09-29-2011
Maine Sail
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I've done exactly what you describe and it works very well. However you may need to double up the thickness of the tape to do so. You'll also want to be 110% sure the cabin sides are clean and free of silicone. This may involve wet sanding.

Some tips.

1- Preset the port into the cabin and then tape very precisly around EXACTLY where you want it to be. I find the blue or green painters tape to work well..

2- Remove port, make sure both surfaces are 110% clean, and do a lap or two with butyl and then CAREFULLY align it with the taped perimeter (hoovering though) and then in one motion press it firmly into place. Once the butyl hits the clean gelcoat there is not much room for "adjustment" so lineit up well the first time.

3- With someone holding the port in place go into the boat and begin installing the trim ring and screws. Coat the screws in Tef-Gel before screwing them into the aluminum port.

4- Tighten the screws a little bit at a time. DO NOT be tempted to squish it all out at once, you can't without damaging things or stripping or snapping screws.. You can use pressure from the outside to compress it to then go back in and take a turn or two on the screws. It can take a day or two (in warm weather) for the butyl to fully compress and be squeezed into all the nooks and crannies. In colder temps heating the port frame will help..

5- Remove residue by making a super ball sized piece of butyl and working at it with a fast stab n' pull motion. Clean up what you can't get with that technique with a damp rag with mineral spirits and you;re done.

6- Give it a few days and if some is still squeezing out re-tighten and clean up ooze.

-Maine Sail / CS-36T

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