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DIY: Replacing old portlights on a sailboat

16,762 Mga view· 22/09/18
sailingcuddles2368
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Our first DIY project on "Cuddles". Old portlights were faded and were installed in place with screws and regular caulking. Old caulking dried out and portlights started a slow leak. When removing old portlights I found out that the old screws were not holding the acrylic in place very well and were really loose. After researching online and asking around, we decided to go with 3M VHB double face tape to install new portlights in place. This is the same tape that used in window installation on commercial buildings. Very tough tape, plus no issues with different rates of expansion between acrylic and fiberglass like the screw in application. Usually with screw in application, we would have to drill bigger holes in the acrylic portlights so the don't crack due to the expansion. Because of that, there are higher chances for a leak vs 3M VHB tape route. Also, after extensive research, went with DOW Corning 795 Silicone which is the only silicone recommended for any kind of glazing, window, portlights sealing. It doesn't dry out as fast as other silicone products, so you can take your time working with it and taping the area off. New portlights were made out of 1/4" thick cell cast acrylic. grey color. Originally was planning on ordering 4x8 sheets and then cutting it, but acrylic was inexpensive enough that I had local plastic shop cut them into correct shapes and sizes. Cost came out around $50-$60 per portlight with radius corners and radius edges. Products used: 3M 5952 VHB tape, you can find it all over the place but this was the fastest shipping for me : https://www.amazon.com/gp/product/B01BU7038A/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1 DOW Corning 795 black silicone, I ended up getting it from local plastic shop, since everywhere else it was taking 2.5 weeks to get it. Price difference was only about a dollar a tube. Ended up using about a quarter of tube per portlight. 1/4" Cell Cast Acrylic grey sheet material. Ended up getting it from local plastic shop, seems like most plastic shops stock it for window or boat applications. Also available in thicker 3/8" but most shops I checked didn't stock it and I had to wait about 3 weeks. You can always try this supplier that was recommended to me: https://www.estreetplastics.com/Plexiglass-Grey-Smoked-3-8x24x48-p/t803752448.htm Goof Off from Local Lowes for clean up and caulking removal. Acetone for cleaning before applying 3M tape. Detail sander to remove existing caulking vs scraping by hand, a lot quicker. Sailboat: 1984 Freedom 32

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