Lewmar Port Replacements

[Jacques C]

It is time to replace my original Gray ports. The Admiral wants Lewmar. Before I spend a lot of money, I would like confirmation that I am getting the right sizes.

6 doghouse ports Lewmar Standard Portlight size 0 overall size 6 15/16 by 12 11/16 and cut out size 6 1/8 by 11 15/16

3 cockpit ports Lewmar Standar Portlight size 1 overall size 7 1/2 by 14 7/16 and cut out size 6 3/4 by 13 5/8

It is my understanding that the cut outs for the original Gray ports is 5 1/2 by 12 1/2 and 4 1/2 by 14 1/2. That leaves very little overlap in length. How has that problem been addressed? Any thoughts? Thanks.
Jacques

 

[Tom-in-Annapolis]

Have you checked these? There are some examples in the project forums.

http://www.newfoundmetals.com/portlights/tri-matrix/rectangular-tri-matrix#size

 

[Mark48]

What about just replacing the Gray lenses, easy and less costly and will keep you on the water. It takes about 5 minutes per lens.

 

[a65sailor]

I replaced the ports on my 34 with Beckson ports. They are the same size as the originals but nicer. You would have to fill the drain cut outs and cut new ones for the new ports. Good opportunity to check the core with the ports out.

 

[Stu Jackson]

I understand that your wife wants Lewmars. Have you shared with her the perpetual leak problems that those ports have had over the years? Becksons are a great replacement for Grays, but I'll bet Grays are still available from Pompanette in Florida. If not, Becksons, which are very similar, are really good. I have eight of them on our 27 year old boat. I've only had to replace three of them in the 16 years we've had the boat. Still made, still supported, still working. After the first two years of production, Catalina changed to Lewmars for the cabintop ports on our C34s. Every skipper I know (and I know LOTS of them) does not like them. They leak. The O rings, an unnecessarily complicated design, need replacing. The screens don't stay in place sometimes when the lights are opened. Among other things.

I'm glad I don't have them.

So, before you jump, carefully consider your options.

Good luck.

 

[quadrille38]

I replaced the Becksons on my Catalina 34 with Lewmars years ago and never for a minute regretted it. The Becksons were held in place by the caulk only and leaked like crazy. The Lewmars have an inside and outside design that clamps them to the opening. And they never leaked. Of course you have to seal them well when you install them.
The Hunter 34 we own now has Lewmars and they continue to serve well. The screens on the newer design were a bit of a poor design with 4 tiny tabs that fit between the gasket and the frame. They tend to fall out and of course sink like stones. They sell a replacement frame on this web site that is a much better design.

 

[Stu Jackson]

The Becksons were held in place by the caulk only...

The Beckson instructions state to use silicone caulk. ONLY that material, NOT butyl tape or anything else. I'm not saying you tried butyl, just to let other people know that Beckson instructions say to use silicone caulk and only that.

It's the ONLY place on my boat I use silicone caulk.

The OEM port installation at the factory could have left a lot to be desired. My re installations work just fine, years later, as do the OEM other 5 ports.

The simplicity of the Becksons compared to the complexity of the Lewmars is simply something the OP should consider.

 

[a65sailor]

The Becksons suggest you through bolt them. I used flathead machine screws counter sunk into the fiberglass. The trim rings cover all screw heads. Finished inside with nuts and acorn nuts to dress it up.

 

[Jacques C]

port replacement response

Tom - I really like everything about the Tri Matrix except how they look on the outside. Mark - Our gray ports are badly chipped on the outside. They are more than 30 years old. The lenses do need replacing but they are not up to my wife's standards in looks on the outside. a65sailor - The Becksons are not that much cheaper than the Lewmars and the Lewmars look better. I'll not like them if they leak however. Stu - I did not realize that the Lewmars had a reputation for leaking. I don't like that. There are more options than I realized. quadrille - Your good report on the Lewmars is encouraging. I have experienced OEM installation of ports by Catalina and was not impressed. Stu - Please explain how the Becksons are more simple than the Lewmars. That may make a difference.

I am going to take off one of the Gray ports & check the actual hole size. The port is leaking and needs to be removed anyway so it can dry out. Thanks for your responses. Anyone out there actually done the refit with Lewmars?
Jacques

 

[Jacques C]

sorry

Sorry quadrille. I understand you did the replacement on your Cat 34. I am interested in how easy it was to accomplish. Anyone out there who has done the Lewmars on a H 34?
Jacques

 

[Stu Jackson]

Stu - Please explain how the Becksons are more simple than the Lewmars.

www.beckson.com shows the details of how they are built. The locking cams are simpler, since they are friction fittings on the opening lenses, rather than a more robust appearing but complicated locking mechanism on the Lewmars, which, IIRC, incorporates an internal O ring. Devil's in the details. The exterior trim ring appears to me to more "forgiving" for installation, although admittedly it is thicker and of white plastic rather than the neater thinner metal trim on the Lewmars. The Becksons are rather simple to remove and replace in the future.

http://c34.org/bbs/index.php/topic,3241.0.html

 

[quadrille38]

Sorry quadrille. I understand you did the replacement on your Cat 34. I am interested in how easy it was to accomplish. Anyone out there who has done the Lewmars on a H 34? Jacques

It was actually very easy. Here are the steps I followed. I used a thin flat blade to work in behind the trim rings on the outside of the coach roof. They are held in place by sealant and if you work carefully they come right off. Next I used the same thin blade on the outside between the port and the coach roof to begin cutting the sealant that holds the port in place. Then go inside and work the blade in from the inside. Once the ports were all out I had to slightly enlarge the holes as there wasn't a same size direct replacement in the Lewmar. My dad is a tool and die maker and he cut a precision template for me to use to mark the size of the needed opening. Then with scrolling saw I cut the openings to size. Mixed up some West epoxy to fill the voids I found and to seal the edges of the wood core. When cured I installed the new Lewmar ports. They port goes on the outside along with sealant caulk. There is an aluminum ring that goes on the inside. Machine screws pull the two pieces together clamping them with the coach roof in between. Start to finish it took a day and a half. Could have done it all in one day but the West needed time to cure.


Was very happy with the results.


In fact if you check the C34 tech notes I posted there after I did the project.

 

[Jacques C]

2 good choices

Stu - Great information. The Becksons are the exact same hole size as the Grays. Quadrille - The specific information will help me when I remove the old port. What year did you post the Catalina tech notes?
Jacques

 

[Stu Jackson]

. What year did you post the Catalina tech notes?
Jacques

Doesn't matter, nothing's changed. Within the past 16 years, cuz that's how long I've had our boat and been very active on our C34 website.