O'Day 27 Portlights

[RMintle]

I have a 1975 O'Day 27, and I want to replace the portlights on both sides. When I try to remove them, they are brittle and crack into pieces. What I would like to do is to 3-D print new ones. Does anyone have CAD drawing files for them?

Or any other suggestions? I haven't found a place to buy them. I successfully changed the plexiglass in the two smaller forward ones, but only 1 of the larger ones in the main cabin needs replacement.

 

[jssailem]

A CAD drawing would be extremely helpful to build your 3d printed replacement. I am afraid that the 1975 date of the boat hardware predates the accessible development of CAD drawings on boat parts like your window frame. Auto CAD for personal computers was released in the early 1980s.

If you invest the time to create a CAD drawing, it would be a valuable assistance to boat owners here with 3D printing capability and support for mature boats.

 

[Project_Mayhem]

I'm very familiar with these windows. I've also had them crack when removing. I managed to epoxy the broken piece into place, sand and then paint. Masking off the window is the most time consuming part. Do not use butyl for this application. The lip/channel is taller than the butyl. If you double up the butyl it will never compress completely when you put the window back in. The edge of your window will forever be collecting dirt from the exposed butyl.

I believe these are bigger than most 3D print beds. D and R marine has the windows for sale.

 

[RMintle]

Yes, they are bigger than most 3-D printers, but I could make them in two halves and join them. It looks like my original ones have a seam.

 

[RMintle]

I just looked at D&R again. I couldn't find them before, and I can't find them now. Does anyone have a link?

 

[Project_Mayhem]

Getting a good seal at the joint may be challenging. Sometimes getting a good seal with standard hardware can be challenging. I often run my printer 24/7 for days on end but this style of manufacturing has its limitations.

From what I understand, the original frame was extruded as a straight piece and then bent over a jig. I don't know if the plsatic was allowed to cool down before bending

 

[RMintle]

Ah, now that I look at it, it looks like that is how it was made. Interesting.

 

[GreggS]

I just looked at D&R again. I couldn't find them before, and I can't find them now. Does anyone have a link?

They don't have them. I'm doing the same on my 1975 O'Day 25 (same shape windows). I'm basically breaking them apart, replacing the plexi, and gluing back together

 

[RMintle]

I am in the process of making the CAD files to 3-D print them all. I should have my first one ready in less than a week.

 

[GreggS]

I am in the process of making the CAD files to 3-D print them all. I should have my first one ready in less than a week.

I'll be interested to see the drawings. Based on my own project, I'm learning FreeCAD at the moment. Can think of several other boat project applications as well. Good luck!

 

[RMintle]

I have made them all. The forward portlights are identical on both sides of the boat. The middle and aft ones are mirror images on the opposite side.

I split them all in the center for 2 reasons. First, so they would fit in the 3D printer, and second, so that one could insert new plexiglass in the slot before they are installed.

I have printed the forward one, and it fits perfectly. I am printing one of the aft ones now.

I viewed the STL files with a viewer, did a screen capture, and put the images in the PDF I am uploading.

 

[Alan Koch]

I have made them all. The forward portlights are identical on both sides of the boat. The middle and aft ones are mirror images on the opposite side.

I split them all in the center for 2 reasons. First, so they would fit in the 3D printer, and second, so that one could insert new plexiglass in the slot before they are installed.

I have printed the forward one, and it fits perfectly. I am printing one of the aft ones now.

I viewed the STL files with a viewer, did a screen capture, and put the images in the PDF I am uploading.

Would those also work on a 1978 O'Day 27, I have a leaking port aft window at least when I pressure washed it the leaked

 

[RMintle]

Yes, as far as I know. Do you have access to a 3D printer?

 

[Project_Mayhem]

Would those also work on a 1978 O'Day 27, I have a leaking port aft window at least when I pressure washed it the leaked

Pressure washers can blow out the sealant. My O'Day had a bunch of leaks after I pressure washed it

 

[Timm R Oday25]

I would be cautious about installing them all right away . I had some parts 3 D printed . I left them in the sun on a relatively cool day . I was shocked when they melted . I am not positive of the exact plastic that was used ..