Core Material around port lights?

[rajhnsn]

We removed, rebeded and reinstalled the starboard salon port light on our Oday 35 last weekend. When the light was out, I noticed that there was no core material between the outer and inner skins. Shouldn't there have been a balsa here? There was about 1/4 inch of space. Has anyone else found balsa in this area?

 

[Erieau]

My O'25 has no core around the salon portlights either. I wasn't surprised about it, as there is no need for structural rigidity in this area. If the boat is heeled over far enough for me to stand on the side of the cabintop, I've got bigger problems than a leaky window.
As it happens, the water coming in through the light's gasket was starting up at the hatch slides. That's the job I'm tackling this weekend.

 

[damauney]

No Core

There is no core in the fixed light to inner liner space in my 1989 O'Day 35.

Goodwinds
DaveM

 

[rajhnsn]

Thanks. This helps.

 

[tcwaltz]

There is no core on my 28. However I filled the void on mine with great stuff foam shooting it on as far as I could go. The insulation factor with this has been huge. After it dried I then trimmed it flush and cleaned out a half inch grove all the way around the port and filled it with epoxy. Since I was using barrel nuts that went through both liner and hull I need something to maintain the spacing when I screwed it together. My ports are great and do not leak. The other bonus is that if there is a leak around the port it wont be going between the hull and liner

 

[25yearslater]

I put 1/4" plywood, epoxy coated, between the liner and cabin side as there was substantial distortion of both that required the seal to hold it in place when the two pieces deformed. Pages 15 and 16.

 

[damauney]

Rajhnsn

On my O'Day 35 the fixed lights are attached to the outside coach top. No attachments to the inside pan. There is a trim ring on the inside but not attached to the outside so the inside and outside can move separately. Seems logical to me to leave it that way on our boats.

Goodwinds
DaveM

 

[Stu Jackson]

Dave, we've had that discussion, too. If one seals around the outside the gap makes no difference. Keep the water outside.

 

[rajhnsn]

Thank you all. The portlight were tested this weekend and no leaks. Port side is now showing leaks so I guess we'll continue as we did the first. Take out the light, clean everything, caulk with silcone, and reinstall. The lights are in good shape so we will not have to upgrade them. Evidently the previous owner knew better that to use 5200.

 

[Pat]

Thank you all. The portlight were tested this weekend and no leaks. Port side is now showing leaks so I guess we'll continue as we did the first. Take out the light, clean everything, caulk with silcone, and reinstall. The lights are in good shape so we will not have to upgrade them. Evidently the previous owner knew better that to use 5200.

Dow-Corning 795 I believe...allows shrinkage and expansion without leaks..Rudy sells this item....is especially important as fall and cooller temps arrive. Pat

 

[rajhnsn]

Thanks. I'll look for it and give it a try.