Installing metal port trim at large fixed ports

[patrscoe]

I just recently purchased a S2 11.0A sailboat. Very happy with it but I'm starting to create a list of projects for this winter and one is the large fixed port lights need to be replaced.

I want a more seaworthy connection and want to have a top and bottom port metal trim installed similar to j-channel. This will allow me to bolt the trim to the topside cabin and allow a much tighter and seaworthy installation for the lexan panel as it will not be able to pop out under rough sea conditions. I would have the thickness be slight more than 1/4" and have the top slightly tapered so that the water would run up and over the metal with ease.

I have read several reviews and comments on these fixed ports, and seems to be a weak area on these sailboats.

Any comments or advice?

Patrick

 

[woodster]

welcome to the forum....

i have a 1979 9.2a and a doing a refit from stem to stern...i removed the fixed port lights due to a lot of crazing...in order to remove them in on pieace i had to use a windshield knife to cut the sealant between the fiberglass and the plexaglass....i figuer that after 31 years if they are that hard to get out then the original way they were mounted is ok by me....i thought about making metal trim work to mount them back but it is very costly and haveing said that i decided to go bake the same way the factory did it ...hunter and catalina both are mounting there fixed lights the same way even up to the 2012 modles so you may not need to go to that intensity to replace them...just some thoughts to ponder hear.....good luck..

regards

woody

 

[patrscoe]

Woody,
I have notice that most newer sailboats have more fixed port lights. They almost seem like glass rather than plastic. I definitely don't want to do more work and spend more money then needed but those 11.0A fixed port lights are so large. Most of the other models, the fixed lights are smaller and less of a risk.

 

[Mark Maulden]

There are some threads about windows here. One of them mine. Check them out. I'd have no issues taking mine offshore wrt windows. My new ones will outlast me....Also, from the outside, they look large. The actual cutout is, obviousy, quite a bit smaller..

 

[BobM]

If the weather is THAT bad perhaps deadlights would be better and easier to install. If drilled and installed some stainless threaded inserts around the ports you could then easily mount the deadlights over the ports and secure them in bad weather. Something strong, but fairly flexible, like thin plywood re-enforced with a layer of biaxial cloth and resin sounds like a plan to me. Roger did something along these lines. You would also be able to keep the looks of the boat the same and installation be as simple as drilling an oversized hole and fitting the threaded fitting with epoxy. If you really wanted it tough you could back them on the interior somehow.

 

[BobM]

http://forums.sbo.sailboatowners.com/showthread.php?t=104620&highlight=ports

Unfortunately, Roger's project page is down, but in the photo you can see the insert in the frame of the port.

 

[BobM]

Just another thought...my friend was in the Almesian when it was pooped by a 40 ft rogue waves. The Captain hadn't thought to install the deadlights (wooden covers) even though he had made the decision to run in front of the storm (he drowned but all the others survived) and the wave blew tempered automotive glass right out like it was tissue paper. My point is...it isn't just how the acrylic is secured, it is that the thickness is likely inadequate too, especially after a few years of sun light. I think the 9.2A has 3/16 to make the required bends forward.

http://www.msc.navy.mil/sealift/2005/june/seay.htm

The first key to the factory install is roughing up the areas of the new acrylic that are to be bonded. I saw a 9.2A where the owner hadn't done that. The new ports were popping right back out. One was lying on the deck when I looked at the boat.

 

[patrscoe]

I am not familiar with our sailboat as we just purchased her so I don't know how seaworthy she will be and hopefully I will not incur any unexpected extreme weather. More or less, I am going off what I read and heard about fixed port designs like the S2 and overtime, even a small wave can take out the ports.

Since I need to replace them due to existing cracks and have time this Winter, I figured to perhaps improve the installation some how. Maybe just going with the original install is the way to go and using 1/4" as Mark suggested.

 

[mark_swart]

I have never heard of a wave knocking out an S2 port. At that point you are talking about a wave big enough to go over the side of the boat....just doesn't seem likely on the bay. I think if you successfully replicate the original installation you will be fine.

 

[BobM]

I agree with Mark. It is really only necessary if you go blue water. My friends accident depicted in the book linked below...was 400 miles off the coast on their way to Bermuda in a storm. Even then, deadlights are a better and easier option. Another thing some due is design an emergency port cover. When you are changing your ports figure out a way to build a cover that would fit over the port if it was knocked out and how it would attach. If it were me, I would cut some plywood slightly bigger than the port and carry my 18V ryobi and some screws. If the boat is going to sink a few holes in the cabin will be the least of my worries!

http://www.amazon.com/Overboard-Blu...=sr_1_2?s=books&ie=UTF8&qid=1319116378&sr=1-2

 

[Mark Maulden]

I just posted some pix of our new fixed ports in our 11.0A. They're in the thread I started. They are 3/8" bronze polycarb. I was waffling between bronze/clear/smoke. I'm glad I chose the bronze. I plan on this boat going as far as Glacier Bay AK and have no reservations. One advantage we have in the PNW is we can choose a weather window where other places can have storms show up out of nowhere........