leaky portlights w/ aluminium frames

rrgane · #1 (**permalink**) 06-19-2007

hey everyone, i just finished up my job of ripping all the deteriorated veneer out of the inside of my I-29, and as we all know each project is pregnant! so a few hours after cleaning up it started to rain and i could now see that the water i was accumulating was coming from my big 'picture window' portlights. they are the kind with aluminum frames that have self tapping screws on the inside that pull the port tight. anyway, i popped the worst offender out, cleaned it up and rebedded it with 4200. well i am quite sure the seal is good, but next rain it still leaked, however i see now that the water is accumulating on top of the lower sill, so my guess is the o-ring around the plexiglass has failed.

i have done every search i can think of to find out what can be done about this, but maybe i am just calling things by a wrong name, or not searching effectively, but i have not been able to find anything. so, has anyone been able to successfully re-seat the plexiglass (or lexan) into their aluminum frames? is there any website out there that shows the proccess?

i have thought about just ix'ing the whole idea and screwing plexiglass to the outside without any frame (you know like how all the slinky new boats have?) and while i think that may be my best bet, i think it might look stooooooooopid on my Islander 29

thanks!!

randall

morganmike · #2 (**permalink**) 06-19-2007

New Found Metals - Marine Hardware and Stainless Portlights

They don't have what you're looking for, but chances are you'll end up here anyway. I did. Good luck.

sailingdog · #3 (**permalink**) 06-19-2007

New Found Metals has had some serious complaints raised against them, so I would be cautious in any dealings with them.

The idea of using Lexan and bolting it directly to the hull is a good one, and far more feasible than you might imagine. BTW, I would use Lexan, rather than Plexiglass, since it is far stronger and more impact resistant. Don't screw it to the boat either—through bolt it as it is a much stronger and safer way to install it. Drill the holes in the Lexan a bit oversized as it will expand and contract a bit, and needs to float around the fastener to do so. Use washers or a trim ring to accomodate the slightly larger holes.

Sailormann · #4 (**permalink**) 06-19-2007

Quote:

New Found Metals has had some serious complaints raised against them, so I would be cautious in any dealings with them.

??? Can you elaborate SD ??? Am just about ready to write a cheque to them...

sailingdog · #5 (**permalink**) 06-19-2007

I've just seen some pretty vitriolic posts regarding them, their customer service and such... so might be worth being cautious. Even if much of it is exxagerated, there is usually a grain of truth to such posts.

Sailormann · #6 (**permalink**) 06-20-2007

Hmm - there are a few people on the CS owners site that have been raving about the quality and the perfect fit... I'll dig a little further..r

rrgane · #7 (**permalink**) 06-20-2007

Quote:

Originally Posted by sailingdog

BTW, I would use Lexan, rather than Plexiglass, since it is far stronger and more impact resistant. Don't screw it to the boat either—through bolt it as it is a much stronger and safer way to install it.

yeah if i do go that way, i would prefer to use Lexan because of it's strength, even though i have read it does not stand up to UV as well as Plexiglass. however, i have a slight curve to the side of my dog house, and i do not think Lexan in the thickness i would use will have the flexibility i would need.

Absolutely through bolting.. the sides of my doghouse are solid fiberglass, so there wouldn't be really anything to speak of to screw into.

Thanks everyone! i am anxious to hear anything about New Found Metals, as i am somewhat close to Port Townsend, and plan to be sailing that way soon anyway.

Freesail99 · #8 (**permalink**) 06-20-2007

New found Metals was offering very deep discounts at the Strickly Sail Shows. May be worth sayng you saw them there.

southerncross31 · #9 (**permalink**) 06-20-2007

Hi All,
I just installed my first of 8 New Found metal ports (4-4 by 10's, 4-4 by 14's) They actually listed the sizes required for my boat..which most places don't have. I am VERY happy with them so far. At 180$ for the 4 by 10's I wasn't expecting them to be so WELL built. They seem far more sturdy than the plastic bomar style ones that i took out. The tempered glass is very thick and the metal seems of good quality. They are spring loaded so they stay open on their own. And the all metal latches are easy to use (not screw down) and seem as though nothing could get through them.
I had the same leaky problems with my old ports and had lexan cut to fit inside them. It looked bad and since i couldn't open them the boat was verey stuffy. Moreover.....i was not about to go to sea with those peices of crap in my boat. All the dog ears were broken off so they wouldn't stay shut! One wave slap and i would be all done!!!! I had to enlarge the cut out with a jig saw to make them fit, but NFM provides templates for a small fee, i would higly recomend using them.
The only downside is that the 4 by 14's were on backorder for 5-6 weeks (as of 3 weeks ago). However, i am so far from launching that it won't be a problem ( I'll just have to wait even longer to get a taste of Buzzards Bay). Overall i would highly recomend the product! You could spend 4-500 per window (Spartan Marine) but i don't think they will be much better (i've seen them on other boats). That said i would love to hear of any compaints so i can be on the lookout. Thanks, Preston

duffer1960 · #10 (**permalink**) 06-20-2007

I just did this to my Catalina 38 three winters ago. I bought the supplies from catalinadirect.com. I know yours isn't a catalina, but the aluminum frames are probably pretty generic. Once removed, the frames seperated into two halves. I was able to purchase new weatherstripping for between the glass and frame, and new trim for inside the frame. It was a fairly easy job to do, the hardest part was cleaning all of the old sealant out of the tracks. I bet you could remove one of the ports and disassemble it and take it to a local window shop and get the proper fitting seal, and I bet for a lot cheaper. I wasn't able to find a direct link on the catalinadirect website for the repair kits, so I did a search for "window repair" on the site and found some matches. Also FYI, the portlights in my Catalina were tempered glass, not lexan or plexiglass.