Crazy Windows

[Mendana]

Hi All, I am about to embark on the replacement all 8 port lights on my S&S 34. She is a very well maintained vessel and i am progressively sailing her more and more offshore, so the replacements must be bulletproof.

I am not sure what to replace them with as there doesn't seem to be anything off the shelf that has the same measurements and I don't want to start cutting different shaped holes in the cabin top to fit production port lights..

Currently the outside is simply perspex glued on with the addition of a dozen or so s/s screws in each port light.The internal trim is teak. The perspex has crazed and cracked at the screws over the years and I reckon each and every one leaks a tiny bit...

I like the perspex as it is very strong, but I don't believe its a good idea to use screws as the perspex expands in the heat and causes the cracking around the screws, ultimately resulting in the leaks.

Is it possible to to have new perspex cut and simply glued on the outside (about 6mm thick) without using screws to ensure a craze/crack free life?...

I'm in Melbourne Australia - Are there any custom made alternatives you can suggest from good local suppliers?

I would appreciate any ideas. Many thanks in advance.

[zeehag]

make the screw holes larger and use more goop to seal em
or do as formosa did--mine have no screws in the plastic part--only in the coachhouse wood. my teak bits are there to keep the goop and plastic in place, with wood overlapping plastic bits. no puncturing of plastic. works well

[TurninTurtle]

Yep... drill the holes a little oversize.

Caution when drilling lexan, plexiglass and other clear plastics typically used for windows. The common drill bits will catch just as you break through the opposite side and crack the plastic. They make special drill bits for the purpose.

using a frame to bolt the window to the boat is one of the better ways around this.

[Nauticatarcher]

Have a read of this, covers most of what you need
How to install boat windows and port lights

[dlymn]

Agree about larger holes and using special drill bits. Do a google search fot "vis canon alu" to get information about the screws to use with plexiglass.

[ErikFinn]

Originally Posted by Nauticatarcher

Have a read of this, covers most of what you need
How to install boat windows and port lights

Absolutely.

And watch this one:

https://www.youtube.com/embed/MQyjxV...ient=mv-google

[Hudson Force]

Originally Posted by Nauticatarcher

Have a read of this, covers most of what you need
How to install boat windows and port lights

I followed this plan for my recent refit of 12 portlights. All done with 3M VHB 4991 tape adhesive and no fasteners. I used the Dow 791 as a sealant for the outer edge.





'extremely pleased!