New Port Lights (aka: windows)

Well, we did it. We bought 4 new stainless port lights from New Found Metals for our 1978, 34. It was a far easier job than I expected it to be. The old plastic windows had an O.D. of approx 5" x 12." The new stainless models were identical except for two small cuts outs. I bought the windows, teak trim rings, stainless steel bug-screens, the butyl rubber sealant and also rented their jig for cutting the openings. The steps we took: 2 hrs each port: Bought new heat gun and putty knife. Removed old screws and applied heat. I wedged the putty knife under the old frames and sealant as it heated and broke the seal. Cal/Jensen used the best when they built our boats. This was the original 30 year old caulk and it BARELY released. It never leaked in 30 years. I fiberglassed over all old screw holes. 1½ hrs each port: I then had to cut out two small openings for the spigots on the bottom of the new ports and drill new screw holes. The rest of the opening fit the new window perfectly. I used their roll of butyl rubber around the window flange and another sealant around the edge of the outside the stainless trim ring. I sanded and teak oiled the teak trim rings before installing them. Once the two parts were mated, I tightened the screws until the sealant started to ooze out around the edges. I cleaned up the sealant with Interlux Solvent 216 which works like magic. I stopped and waited for everything to cure a few hours. Then I finished tightening. I posted a couple "before and after" shots in my Sound Discovery photo section here.