H30 Portlight R&R

[malyea]

Just finished installing 8 new Gray portlights in the cabin, head and V-berth and have only the last remaining one in the port quarter berth that opens to the cockpit just below the port side seat.

We occasionally clip an ankle bone on this one as it extends out from the cockpit seat side wall a couple inches and I was thinking.....

What if I trim the extending frame rim back by maybe 1" to 1 1/2" leaving only 1/4" to 1/2" frame extending into the cockpit so we clip ankles less frequently...?...?

Would that impact any functionality or rain shedding issues? That portlight is closed 99.999% of the time.

How would I best trim the plastic frame to end up with a nice cut and finish - dremel tool, hacksaw, planer?
- treat it like woodworking and finish sand it with 320 grit?

I do have a few old ones to practice on...

 

[Steve Dion]

I would use a grinder or a belt sander to take it down. I would make it as flush as possible. It hurts like hell when you tag one of those frames. It sometimes turns into a bloody mess.

Be sure to radius the edges all the way around the port extension too.

 

[kloudie1]

Another option is to use an oscillating "Multitool". Fein makes the best one but there are a few good (less expensive) ones out there for not much money. Mark the extension carefully, using the old trim ring as a guide, then cut with the half moon blade, then finish the edge very carefully with a belt sander .
http://www.harborfreight.com/power-tools/oscillating-tools.html

 

[malyea]

Thanks to both -

Steve - When you say "Be sure to radius the edges all the way around the port extension too." - do you mean round the edges with sanding to avoid having a sharpe edge on the port extension?

 

[Steve Dion]

Yes!

 

[malyea]

Thanks for the "how to"... Now how about "should I?"...

I'm trying to think of any reason not to trim the portlight extension from almost 2" down to about 1/2"...

What purpose does the extension serve (maybe like rain protection from an awning if I have the portlight cracked open for ventilation during a shower) and - will I miss it or regret it if I trim it down to 1/2" extension?

Any thoughts?

Thanks

 

[Allan12210]

I think the port extension is just what happens with a "one size fits all" design. If the hull was thicker, there would be less protrusion and rain would not be a consideration. My friend a few boats down with a H37C replaced all his ports down the cabin. The thickness of the cabin was not constant so the extension increased to the forward ports. He did not like the way that looked so he trimmed them. There was no consideration for rain protection as those ports tilt up anyway. Rain can come from any angle. There are a lot of designs that have no extensions. I think it will come down to what looks right to you and is functional. The same footwell port on my H34 has a flush extension.

Allan

 

[malyea]

Thanks, makes sense. I'm going to practice on an old one and if I get good results will be trimming it down.

Thanks to all

 

[sandpiper10471]

Trim it. My H33 had the trimmed cockpit portlight. My 37C doesn't. Another job for me to get around to. The excess flange is totally unnecessary and really does get in the way and cause pain. Can even draw blood.

 

[malyea]

Once I make the cut with either a multitool or dremmel, how do I finish/sand the now rough surface of the fresh cut?

Can I treat the plastic edge just like wood and use progressivley finer grits of sandpaper down to say 320 or finer to get a polished edge?

 

[malyea]

FWIW...carefully marked the portlight and made the cut with a dremmel - turned out VERY ROUGH along the cut edge. Initially sanded with 80 grit course sand paper then 180, 320, 1000, 1500 and finally 2500 (wet sanded with 2500).

Looks great! Plastic sands like soft pine and took less than 30 minutes elbow grease. Ahh, the little victories! Pass the rum ;-)

 

[H30Gary]

Wow, sounds great! Did you trim it flush or leave some extension?

 

[malyea]

Left about a 1/2" extension just because that was easier than trying for exactly flush.