New NFM Portlights on Morgan OI 30 - Issues - SailNet Community

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Old 07-05-2012
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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.
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Old 07-16-2012
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Re: New NFM Portlights on Morgan OI 30 - Issues

Fortunately, I had some good luck. After letting the boat sit out in this interminable heat for a few weeks with the port lights out, the wood dried out. It seems pretty solid now. I'm going to make a frame to hold the width and shape, and then fill it with epoxy. I think it will be solid.

Unfortunately, the Morgan OI 30 doesn't have all that much wiggle room to install these. I'm a bit nervous that I'll have enough clearance. But I'm sunk in the project, so onward we go!
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Old 07-16-2012
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Re: New NFM Portlights on Morgan OI 30 - Issues

If you need it, NFM has metal patterns/templates for their ports. It might be suitable to use as a router template or to make one. It looks like you would have more room on the top. Maybe just a little sanding with a Fine type multi too and a drum sander might make it an easier fit.

If you are replacing old plastic ports you'll love the NFM ports. Replaced mine a few years back. They are great.
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Re: New NFM Portlights on Morgan OI 30 - Issues

I ordered the router template, unfortunately, it's too big. On the outside I'm bound on the bottom by my rub rail. On the inside I'm bound by the cabin top. It's a real pita, and requires a lot of fiddling to get them in.
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