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post #16 of Old 08-17-2017 Thread Starter
Chas H
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Re: Replacing Deadlights

It was not as difficult as I first imagined and with good advice from contributors it looks great!

Used a putty knife to carefully separate the frame from the cabin. I think they were bedded in butyl.
The plexi pushed out of the frame with no effort. The old gaskets fell apart.
Sanded the frame contact surfaces with 120 grit sandpaper.
Buffed the plexi faces by hand the with 1000 and 2000 grit Aqua Buff compound.
Sanded the faces of the plexi around the perimeter about 1/4 inch from the edges with 600 grit wet or dry.
Laid the frames on a flat hard surface.
Squirted a small bead of 795 around the frame where the plexi seats.
Inserted the plexi into the frame.
Squirted another bead of 795 around the perimeter on the outside surface of the plexi.
Put weights on the plexi and waited for the 795 to dry. The 795 shrunk into a nice fillet.
Sanded the gel coat on the cabin sides where the frame seats with 120 grit sandpaper.
Squirted a bead of 4000 on the cabin side.
Screwed the frame in place.
I added more 795 around the perimeter of the plexi and formed about a 3/16 R fillet.
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