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Main Saloon Portlight Rebedding

2011/09/10 - In the main saloon, the first step is to remove the eight screws that hold the frames together. Keep track of which screw comes from which hole, as the screws may be different lengths!

Since I've had these portlights apart a couple of times, I know how they were installed and that there is lots of bedding compound holding things together. Be careful prying things apart so that the casting doesn't break or bend. That would be bad!

With the inner frame off, there is nothing holding the portlight in except for the bedding compound. Using a wide putty knife, start working out the frame a bit at a time. Again, care must be taken not to bend or crack the frame.

Once the bead on the portlight has been broken, it can be gently pulled from the hole in the deck house. The next step is to clean off the bedding compound from the frame and plexiglass. For reference, the plexiglass is 3/8-inches thick.

Finally, the hole for the portlight can be cleaned up as well so that there will be some clean surface for the new bedding compound to stick to.

2011/10/15 - Bad weather outside today gave good reason to move indoors, so the portlights from the main saloon were cleaned up and made ready to be remounted once the deck painting is complete. The first step involves removing the plexiglass (polycarbonate?) from the frame.

This is done by carefully breaking the seal between the bedding compound (RTV silicone) and the plexiglass. We have to keep in mind that the frame is cast and could be brittle. We don't want to bend or break it since we don't have spares!

Once the seal is broken, the "glass" can be lifted out of the frame.

Once removed, the edges of the glazing need to be cleaned so that, when rebedded, they are less likely to leak.

Not just the surfaces, but the actual "edges" of the panes need to be cleaned of all old bedding compound.

With the glazing removed, attention can now be turned to the frames. All of the old bedding compound needs to be removed to ensure a watertight seal when it gets reinstalled. A sturdy putty knife is the best tool for this.

2011/11/27 - As you can see by the gap in dates, there has not been a lot of activity. This was partly due to work schedules (too busy) and partly due to weather (too crappy).

Thanksgiving weekend, however, proved to be mild and pleasant both for lack of poor weather and lack of poorly scheduled work. As a result, all of the portlights have been put back into place and the three main hatches have found their way back onto the boat. My guess is that I will likely be recaulking a portlight or two next summer, but generally things went well as everything was replaced.