Join Date: Jan 2008
Location: Seal Harbor, Maine
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Re: portlite replacement I-28
Well I have been "Away" for a while. Sailed our catboat this season; building a house! I do have a few pics of what I did. TD is still under its tarp. I have not removed the masking paper from the acrylic yet. Anxious to see how the vhb tape and the Dow 795 look as seen through the acrylic. I might "frost" a border if their looks are intolerable. I don't expect leaks and 3/8" cast acrylic should defend against any waves we might encounter sailing along the Maine coast. Ha!
Prep of the portlite openings involved a rotary sanding to smooth them out. The outside (gelcoat) surface that will be bonded to the new portlites was sanded and picked at to make sure all loose material was removed. WEST epoxy coated the surface involved and was sanded back to the gelcoat surface filling in irregularities and sealing the old gelcoat.
I made 1/4" patterns of the portlites and I cut "shoes", jigs, that the patterns fit into using 3/8" plywood. I marked the overlap on both sides of the patterns so I could fit the patterns onto the outside of the cabin from inside looking through the portlite opening at the back of the pattern. With the patterns in place I fitted the "shoes" to the patterns and screwed the "shoes" in place on the outside of the cabin. 3 screws each. Test fit then removed shoes to get them out of the way while I applied the vhb tape. After the tape was on I replaced the shoes, removed the backing and set the acrylic into the shoe. My knee applied pressure to make sure the acrylic was attached, removed the shoe and with padding and a deadblow hammer I set the new portlites into the vhb tape. There was a slight curve in the larger opening and I needed to make sure the vhb was totally involved. The vhb has some thickness and leaves enough space to force Dow 795 into around the portlie perimeter. I allowed for a 1/4" wide bead of Dow 795. NO SCREWS.
Hoping it works. Here are a couple of pics. To be continued.
Islander-28, Marshall Sandpiper
Last edited by downeast450; 10-27-2016 at 04:08 PM.