Replacing lens on the fwd hatch, Hunter Legen 40.5, built 1993

[Irek]

Hi guys
I wonder if anyone tried to replace the lens and the gasket of the Bomar 1049 - 10AX4, low profile hatch cover. On the internet there is UTube showing someone pushing the lip of the gasket between the lens and the frame after the new lens was installed. That is next to impossible as the space is full of caulking and in effect the lens is pushed out of the lid's frame. Looks to me that gasket should be installed on the lid first and than lens floated into the caulking. The gasket has a strange shape with some appendages which are difficult to u/stand why they are there. See sketch in the attachment.
Does anyone have a proper procedure fm Bomar on this work? The one that I have received from Mike T. doesn't say anything about gasket installation./ik

 

[Rick D]

I paid a jobber to do mine. Over my head to DYI.

 

[Irek]

Hi Rick, guys
I have completed a job by now and it seems tb OK. Winter time heavy weather will be the final proof of the work.
Few lessons that came out of it:
1. One can buy proper gasket (do not not try anything but original shape) for about CAD 24 per ft or a replacement kit of 9 ft for about CAD 70. Looking around safes money,
2. West Marine (in Chapter 11) closed some shops but the others are still going. I bought my kit Anacortes. Bellingham is closed by now,
3. The best way to do this job is replacing the lens and the gasket at the same time. Trying to push the gasket in the space between installed lens and frame of the lid of the cover can end up with the lens pushed out,
When placing gasket in place (before floating lens on it) use a bit of super glue to attach gaskets in the corners to the frame,
4. Watch out for the last leg of placing gasket before gluing the ends together. It is easy to pull the gasket out of the corner a bit in order to close the gap; make it a bit longer so the corner will be pressed in,
5. For caulking the lens in the frame I used Life Caulk Black (polysulfide based) which dries a bit longer but connection is quite flexible. Apply liberally after proper masking as it seems to shrink when it fries. Note, originally recommended by Bomar caulking could not be found in Vancouver.

 

[jssailem]

Great write-up @Irek

 

[Irek]

Thx. I hope it will be useful. And I usually ask the questions (and great good responses from out members) so I hope I could contribute this time./ik