leaking portlights

[Carolyn1964]

I had hoped to post pictures and share my succcess at rebedding my portlights but alas Here I am with portlights that still leak. I havea lovely 1979 venture 25 and in preperation for this years sailing I had planned on rebedding the portlights since they were leaking last year. I carefully read Maine Sails info on rebedding and on the butyl tape and I got my Butyl from him I thought I was well prepared. I removed the old portlights and cleaned them very carefully with M.E. K. and acetone to be sure and remove any possible reside from silicone or any other product. I did the same thing to the fiberglass. Cleaning those portlughts took much more work than I had thought it would but after 2 days and a ton of steel wool I thought we were ready. We placed the Buytl on the edge of the opening and put the portlights back in and then tightened the frames down . I made sure to tight the frames carefully and balance tigthening one corner then the opposite corner and so on so that the portlight would be drawn in evenly. Since I live inthe beuatiful Pacific Northwest today I had a steady rain so I could check on the job. The butyl shows around nearly every edge and I had thought we had a good seal. But no luck I have 4 out of 5 portlights leaking.... Please help with any ideas on what might have gone wrong or how to do the job successfully. Currently my sailing partner wants to remove the portlights and apply plexiglass to the openings. I am not sure about htat as a plan. For now I am sitting here crying in my beer. :cry: please help:cussing:

Carolyn
damp and downhearted

 

[caguy]

Sorry to hear about your misadventure. I re-bedded one of my frames with tube of butyl sealer. I was amazed how easily the old sealer came off. The manufacturer used what looked like butyl and it was still soft pliable and sticky. After scraping the majority of it off with a putty knife, I was able to clean the frames and gelcoat pretty easily using some paint reducers and rags. I only did the one window that was leaking the worst. It hasn't leaked yet this winter and we have also had some good rains.
I had planned on using butyl tape because I had read a lot of good things about it. The 1/16'' tape seemed a little thin and it was concerned that it might not fill in irregularities or warps in the frame. I bought 1/8'' x 1'' on line at ebay. I used a little to bed the deck mounted waste and water through holes. It seemed to compress nicely though I haven't checked it for leaks. I'll do the next window with the tape one at a time to see if it works.
Thanks again,
Frank

 

[THECUSCUS]

Carolyn
I too have a 79 V25. That being said I feel your pain as my portlights leaked also and I have re-bedded them, so I know the drill. Not to be ignorant here, but you did bed each portlight in two places? #1 being around the plexi in the frame(you need to take the 2 halves of the frame apart) and #2 being where the frame meets the hull opening. The original seal for #1 was a rubber U-shaped gasket (you can still get at a glass or mirror shop). #2 was 1" double sided foam tape.
I took my frames apart, cleaned 'em good, got new plexi pieces made, then took everything to a glass shop and had them put it all together using the U-shaped gasket. Cost was less than $50, parts and labor.
I then bought some 1" wide rubber weather strip(tape on one side, 1/4" thick I think) at Lowe's and ran it around the outer edge of the frame. When you tighten all the screws on the inside, it will compress the rubber, making a nice seal and if you have to take the portlight off, nothing will be stuck to the hull.
I will admit that the glass co did a poor job of the gasket installation, and I had some leakage which I fixed by running a bead of clear silicone around the plexi.
Also, make sure you seal the joint where the two halves of the frame come together very liberally with silicone sealer. This is where water can work its way in, bypassing the seal between the frame and the hull.
Hope this helps some.

 

[Carolyn1964]

Thanks for the inout Frank and Cuscus =) I am planning on a second attempt after the rains leave us. I guess this explains why the boat yards get such a high price for this type of job.... I haven't given up yet

Carolyn

 

[caguy]

I think I would test the rubber seals between the glass and the frame by laying it flat and filling the frame with water. Then check for leaks. If no leakage I would not disassemble frame..

 

[Timo42]

In the middle of replacing mine, replacing the crazed clear plexi with medium tint smoke, used 2 layers of Mainsail's magic butyl tape, new glass moulding, get about 20', lots of soapy water to assemble, antiseize on the screws during reassembly. I'll get some pics later.

 

[Carolyn1964]

I am thinking that doubling the buytl would help my problem. I had two portlights that had to have the frames taken apart and but the rest of the frames were water tight. I have to wait for the rain to stop ( sometime in July, I think) but I will try doubling the butyl and see if that helps. Thanks again for the help

Carolyn

 

[Timo42]

The holes in the cabin top aren't very accurate, you may need to adjust the position of the assemblies to get more contact surface.

 

[caguy]

Timo, I think by the time we get the windows to stop leaking it will be summer. Although the way you like to buiry the rails it's probably a good idea to make sure they don't leak. Weather is starting to look pretty good. I put in a new 9 gal gas tank and motor should run like a dream. My back has been out for the last two weeks (Sciatica) and I've been in bed the whole time. Hope to get back out there by next week. No heavy lifting though so I need you to crew for me. BTW got launch and retieval down to an art. Adds <5 mins to both.
Don't mean to highjack thread Carolyn but haven't sailed with my bud in a while.
Frank

 

[flynfol]

Replaced my plexi last year. Local glass shop had the vinyl U channel. RV butyl tape worked well (1" x 1/8"). Before you replace the small piece of aluminum that holds the frames together, inject silicone in one hole until it extrudes from the other, than screw together. JB Weld the frame joint from the backside, sand flat.. Butyl will ooze for a couple days , but comes off with a knife. So far ...leak free.

 

[Freedom77]

I recaulk anything that needs recaulking with Boatlife. It's real good stuff. Hey Carolyn what's with all the rain up there. Talk to some friends on Victoria and there getting weary of it. Fair Winds, Full Sails and Sunshine.