New NFM Portlights on Morgan OI 30 - Issues
So, I received 7 new, shiny stainless port lights last week. I headed up yesterday to begin the work of installing them. That's when I discovered that Charlie Morgan had specifically designed the 30 foot Out Island to accept only the Gray Enterprises ports that were installed at the factory. There isn't an extra inch of room. Ultimately I managed to squeeze the first one in, but haven't fully installed it yet because of some concerns about the core.
The deck is cored, the hull is not, and the hull/deck joint is right along the rub rail. Apparently these windows have leaked and I didn't know it. As a result, the wood is wet and rotting around the windows. That might be easily workable, but there is about an inch of fiber glass under the windows, pictures attached.
The only thing I can think to do is use the router, picks, whatever to gouge out the wet wood. Then I'll replace with new wood, epoxy it, and let it set. I'll have to tape the bottom of that edge to keep the epoxy from seeping out. Any other great ideas?
Yes, there is a big void there because the original wood simply fell out.
The last pic is the new port light dry fit though, they'll look splendid once we replace the wall covering and put the trim edge back up.
1978 Morgan OI 30
Au Gres, MI