Cal 39 Fixed Port replacement

[jackcal39]

Anyone out there have info on how to replace/repair fixed ports on a Cal 39? I have removed the starboard port window over galley but all exterior frame pieces broke.

[Calif.Ted]

Try calling Mark Plastics in Corona, CA, they have many of the ports originally used on boats.
http://www.markplastics.com/

[Adelie]

You can cut oversized panes and thru-bolt all around the perimeter.
1/4 to 3/8" acrylic with bolts spaced 12 times thickness of pane or cabinside whichever is less.
Holes in pane 3/16" oversized.
Use silicone bedding.
Tighten bolts loosely or use temporary spacers under pane edge. Once silicone kicks, remover spacers and tighten bolts more.
I'm going to to try stainless Chicago bolts on my boat.

[UNCIVILIZED]

I know that some deadlights are actually glued on. Possibly using VB tape? There are discussions on installing new plastic deadlights both here, & over on Sailing Anarchy Forums. With there being a recent/active thread on this, on SA Forums.

[Cheechako]

Pics would help.

[neophytecruiser]

I bought my 1982 Cal39 MRK III in 2005. One of the projects required was to re-bed all the ports. We ran into the same issue with the deadlights. Calif.Ted offered the solution, should you wish to maintain the same frame solution for your deadlights. They will manufacture replacement frames for you boat.

[first wind]

Originally Posted by Adelie

You can cut oversized panes and thru-bolt all around the perimeter.
1/4 to 3/8" acrylic with bolts spaced 12 times thickness of pane or cabinside whichever is less.
Holes in pane 3/16" oversized.
Use silicone bedding.
Tighten bolts loosely or use temporary spacers under pane edge. Once silicone kicks, remover spacers and tighten bolts more.
I'm going to to try stainless Chicago bolts on my boat.

i have seen that done. personally, i find it unattractive and cheap looking. but that's just me. not so sure how strong such portlights are compared to ones installed with frames, like the original.

[first wind]

Originally Posted by neophytecruiser

I bought my 1982 Cal39 MRK III in 2005. One of the projects required was to re-bed all the ports. We ran into the same issue with the deadlights. Calif.Ted offered the solution, should you wish to maintain the same frame solution for your deadlights. They will manufacture replacement frames for you boat.

do they have the manufacturer's specs or do you need to send them yours?

[Steven UK]

Try this, from memory I think he uses tape as per civilized 's comment...

http://youtu.be/Hav2sUGeoHI

[ebsail]

I also removed my fixed windows and replaced them with new ones cut out of acrylic. Oversizing the drilled holes for the bolts is critcal to allow slight expansion or contraction of the acrylic withour cracking the window. Use a special bitt meant for drilling in plastic. Whoever sells you the acrylic (or Lexan) will have the bitts. But don't use silicone to seal. Use butyl rubber tape which will move slightly and still seal the window. It's used for car windshields. I now use it to seal everything, including through the deck stuff like cleats portholes, shrouds etc. We now have a dusty bilge. Unfortunately I think the bilge pump rubber is drying out and may no longer be useable

[jackcal39]

thanks to everyone with the solid advice. Got a hold of Mark at markplastics and getting what I mend. Thanks again.

Jack