I need to replace the port and starboard fixed portholes (plexiglass) on a 1996 Hunter 280. The plexiglass does not appear to be screwed down so I need advise on how to remove and reinstall a new plexiglass.
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Just cut out the caulk
I had to replace my starboard portlight (plexiglass) when a bowsprit went through it without warning. I called my Hunter dealer to replace the plexiglass and get instructions. What they told me to do worked. The plexiglass isn't fastened down; it is sealed into place with black caulk, similar to 3M 4200. The dealer sent the caulk to me with the replacement. Remove the old plexiglass and scrape out as much of the old caulk as you possibly can. Make sure everything is clean and dry before you try to bed the new plexiglass. Apply caulk over the same area the you removed the old from, and use a spreading tool to get its thickness fairly consistent. Use a pair of suction cups on the plexiglass so you can support it as you lower it into place. Have someone on the inside of the boat support it to and help you guide it. Taking things slowly and carefully you can do a job just as good as the factory.
I had to replace my starboard portlight (plexiglass) when a bowsprit went through it without warning. I called my Hunter dealer to replace the plexiglass and get instructions. What they told me to do worked. The plexiglass isn't fastened down; it is sealed into place with black caulk, similar to 3M 4200. The dealer sent the caulk to me with the replacement. Remove the old plexiglass and scrape out as much of the old caulk as you possibly can. Make sure everything is clean and dry before you try to bed the new plexiglass. Apply caulk over the same area the you removed the old from, and use a spreading tool to get its thickness fairly consistent. Use a pair of suction cups on the plexiglass so you can support it as you lower it into place. Have someone on the inside of the boat support it to and help you guide it. Taking things slowly and carefully you can do a job just as good as the factory.
Fishing Line To Remove Old Portlight
To add to MikeH's good advice, Hunter told me to string a 3-foot length of 60# test fishing line through the caulk from the outside into the inside. Then, with 2 people (one on outside, one on inside), pull the fishing line tight and pull it around the window perimeter. The fishing line will cut through the old caulk. I haven't tried this yet, but plan on it in a couple of weeks. Hunter advises using Dow Corning 795 for caulk. In the archives, some folks advise using Lexan (polycarbonate) instead of plexiglass (acetate). Comments from others will be useful. BrianW
To add to MikeH's good advice, Hunter told me to string a 3-foot length of 60# test fishing line through the caulk from the outside into the inside. Then, with 2 people (one on outside, one on inside), pull the fishing line tight and pull it around the window perimeter. The fishing line will cut through the old caulk. I haven't tried this yet, but plan on it in a couple of weeks. Hunter advises using Dow Corning 795 for caulk. In the archives, some folks advise using Lexan (polycarbonate) instead of plexiglass (acetate). Comments from others will be useful. BrianW
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