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Old 03-05-2010, 18:47   #1
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Strengthening Portlight Holes in Cabin Wall

Ahoy, I have to seal all portlight holes for re-installation of smaller porlights, any ideas on how to get a real strong repair in the 1" thick cabin, before cutting new holes for portlights? I know the best way is to use the existing holes but I got a deal on 6-5"x9"x 3/8 glass aluminum opening portlights to go in 6"x16" holes that were merely covered with plexiglass! I want strength in this repair so seeking advise...... thanks for input For '76 Columbia 9.6 #42
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Old 03-05-2010, 19:33   #2
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Just replace it as you would rotten core. New glass, new core. Then cut away the new hole. Seems like a lot of work. Maybe it wasn't a good deal after all!
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Old 03-05-2010, 20:53   #3
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I had a bunch of rot in mine; fixed them up with some epoxy. Might be what you're up to as well. link
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Old 03-05-2010, 21:06   #4
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I replaced mine. Well, I had it done. But I participated under the direction of a professional.

Is your cabin really 1" thick?

He had my buy plate fiberglass. Way tough stuff. He shaped that to take up the gap between old and new. I also ground down cabin material from the outside so the overlay material would be laid up thick. Glassed it all in. Not as bad as it sounds with the plate material. Got it at a place called "Plastics Depot" if I remember.

Very worth it. Took years off the boat with more modern portlights and hatches.
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Old 04-05-2010, 10:44   #5
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stengthening portlight holes

Thanks for input, It seems that glassing in old holes is sufficient into beveled sides of holes, thanks for link, am clearer now what will work. It is a lot of work but well worth it! Scored 6- 5"x9"x3/8" glass, rectangle, opening, aluminum portlights from a salvage shop so I'm stoked!
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Old 24-05-2010, 08:27   #6
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Strengthening Portlight holes

Project on no schedule, proceeding, posting pictures, have carpentry experience? Don't be intimidated! It is like any other medium an artist would work in....wood, metals, ceramic, fiberglass, epoxy....there is so much info on the net (God in a box!) or the other guy! But the collective consciousness is here man! My info is no different, just lose the fear and go for it!
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Old 31-05-2010, 08:24   #7
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Strengthening Portlight Holes

What a wonderful opportunity to be able to post progress on projects!
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