CAD file for portlight frames

[GILow]

Hi all,

I'm rethinking my bronze portlights, there is simply so much work in restoring them, at the end of which I'm still stuck with heavy and badly designed portlights that will leak with the slightest provocation.

One option I am looking at is to have new frames cut from aluminium and make my own design. I figure someone might have a CAD file already for such a thing. They are a pretty common size for the era.

I know a new file would be simple enough for some to create, but there are questions around things like the corner radii that are less easy.

Picture attached, any suggestions?

Also, I'm still thinking about the aluminium thickness, I think 5mm will be too thin.

Matt

[Spot]

Matt, is the current outer frame the same dimensions as your sketch with a keyhole for the spigot?
Will it fit on an A3 copier?
Scan the flat side on a copier with a couple of rules flat on the copier glass for scale.
Give the scanned picture to someone with CAD chops and let them go to town.
Plot the CAD on paper 1:1, cut out, test for fit.

[Pauls]

Could you please explain why the bronze portlights are more prone to leakage than those made from aluminum?

[GILow]

Originally Posted by Spot

Matt, is the current outer frame the same dimensions as your sketch with a keyhole for the spigot?
Will it fit on an A3 copier?
Scan the flat side on a copier with a couple of rules flat on the copier glass for scale.
Give the scanned picture to someone with CAD chops and let them go to town.
Plot the CAD on paper 1:1, cut out, test for fit.

Clever trick... all I need is a photocopier.

There is no current outer frame to copy, this is a build from scratch idea I am investigating. Until I know the cost of rhe frames I won't be able to decide which way to turn. But if I can afford to do it this way it will save an incredible amount of work and should work better than the existing portlights which are really not suited to the installation angle.

[GILow]

Originally Posted by Pauls

Could you please explain why the bronze portlights are more prone to leakage than those made from aluminum?

Totally different design. Nothing wrong with bronze but the existing portlights are very complicated and pool water due to the angle of the cabin trunk sides.

[Spot]

Originally Posted by GILow

Clever trick... all I need is a photocopier.

There is no current outer frame to copy, this is a build from scratch idea I am investigating. Until I know the cost of rhe frames I won't be able to decide which way to turn. But if I can afford to do it this way it will save an incredible amount of work and should work better than the existing portlights which are really not suited to the installation angle.

OK, my bad, did not understand this was a new design.

Regular photos work too but key features need to be backed up by measurements.

[GILow]

Originally Posted by Spot

OK, my bad, did not understand this was a new design.

Regular photos work too but key features need to be backed up by measurements.

You weren't to know I was going down such a radical path. [emoji16]

The current bronze portlights are very nice (if you are into that sort of thing) but there's about two days of work in restoring each frame. There are 12 frames. Eeek! And then they will still suffer from the sill sloping the wrong way.

This aluminium frame idea would allow me to replace all 12, plus fit up to 6 new portlights, in a non opening manner, with just a few days work. Then later, when I have time I can convert them to opening where it would help with ventilation.

What you have drawn there seems to address the very question that was on my mind, namely the corner radii. [emoji106] Thank you.

[GILow]

Originally Posted by Spot

OK, my bad, did not understand this was a new design.

Regular photos work too but key features need to be backed up by measurements.

And thanks also for 1/4" thickness suggestion. Feels close.

[Spot]

You are welcome. The radius could be a hair bigger on the inside depending on the look you want. I would add the frame's width to the inner radius to make the outer radius regardless.

[GILow]

Originally Posted by Spot

You are welcome. The radius could be a hair bigger on the inside depending on the look you want. I would add the frame's width to the inner radius to make the outer radius regardless.

I rather like the proportions you've chosen there already.

The final aesthetic of the boat is yet to be determined anyway, what you've drawn feels like a good place to start.

Incidentally, I'm thinking of a double width version for the bit of the cabin trunk closest to the cockpit. It already has an extra long non-opening portlight there, but for some odd reason it is a different shape to the other portlights. Some boats put two normal sized portlights in that position but it looks a bit crowded and imbalanced to me.

Oh yeah, and two into the cockpit on the aft face of the cabin trunk and onenor two more on the aft face of the aft cabin trunk.

18 portlights in all!

[Dave_S]

I'm not 100% what your asking.

If your looking for someone to draw it up in CAD, it seems quite simple so I'm happy to do it for you if you communicate precisely what you want.

[GILow]

Originally Posted by Dave_S

I'm not 100% what your asking.



If your looking for someone to draw it up in CAD, it seems quite simple so I'm happy to do it for you if you communicate precisely what you want.

Thanks mate, all good now I think.

I was firstly checking to see if anyone had such a file already, given how it was such a common size, but also looking for guidance on the corner radii, which has been forthcoming.

[bil56]

where are your portholes fitted?
inside the hull and screwed/bolted?
the metal frame is just an interior trim?

[Rumrace]

Yes I have a complete cad file for a marine portlight dual lens you can produce any size on a 3D printer. EST 80 hours printing time per portlight. You can have the data buy a printer or take the data to a local 3D printing nut. We are everywhere armed with kilos of high tech poly. ASA in white will make your boat look dirty. It’s titanium white and won’t fade in sunlight. ASA is like the new ABS way stronger.
You could print them in a Nylon infused with carbon fibre for a submersible.

[Spot]

Rumrace, I sent you a PM about the files. Neat idea!


Matt, here are some different radii. I like your original sketch best too: