Portlight reassembly

1

Replace the rubber gasket window seal. Your boat manufacturer or window seal specialist might be able to supply suitable spare gasket material. Providing them with the measurements you require and maybe send them a short section of the old gasket to be sure.

2

Fit the new rubber gasket into the frame, pushing it well into the corners to check the length required. Cut the rubber approximately 25mm overlength to make a really tight butt joint. Ensure the butt joint is at the top. 3

Remove the gasket and apply a bead of silicone into the window pane seal and fit the window to the gasket. 4

Apply silicone sealant into the channel of the frame and fit the window pane and gasket to the frame, bedding it gently into place.

5

Reassemble the frame around the pane. If some of the sealant oozes out, clean this off before it cures.

6

Dry fit the reassembled portlight from the outside. Then apply masking tape all around the edge of the portlight to the hull.

7

Remove the portlight once again, wiping around the edge of the opening with acetone.

8

Apply silicone adhesive or suitable caulking all around the opening. 9

Fit the portlight in position and hold it in place with tape. Better still, have someone outside temporarily hold it in place for you.

10

From the inside, refasten the inner frame to the portlight, tightening the screws little by little to ensure they will all fit properly and to ensure the portlight beds down evenly. Also, take care the portlight does not shift around as you tighten the screws. Allow the silicone to cure before fully tightening the screws later.

11

Clean up the outside, running a sharp blade around the edge of the frame and then remove all the tape.