Replacement portlight glass

[IslandAlchemy]

Just thought I'd post here in case this is of interest to anyone else.

My portlight lenses are all crazed (the long ones), and I've decided to replace them, but with fixed lenses.

I have designed a lens that will fit directly, and is made from 10mm grey tinted cast acrylic (standard Lewmar lens is 8mm, so these are thicker and stronger).

I am getting some laser cut, but as it's a specialist material, I need to buy whole sheets at a time.  They are coming out at about £50 each, so less than a third of the price of Lewmar replacements.

I'll post some photos of them and fitting etc, once they arrive.

If anyone else if interested in these, let me know and we might be able to get some batches done.

[IslandAlchemy]

Quick update.

They can get 24 out of a sheet, and I have to buy a sheet.

So I will have 24 of these windows, although I only need 8.  So I will have 16 spare.

They are coming out at just under £40 each +vat if anyone else wants some.

[Jeffatoms]

I've been considering the exact same process.  Mine are Gebo.  Wondering if you would kindly include a CAD drawing in jpg or pdf of the dimensional cut-outs as it seems many sizes, brands and models have been used over the years.

Thanks in advance!

Jeff & Sue
SV Zephyrus
BAV 38 Ocean

[tckearney]

are these the same on all Bavarias mine is a B42

[IslandAlchemy]

There were different makes and styles used over the years.  Pre-2000ish boats used Gebo windows, and then from about 2000 until 2008ish, they were Lewmar.  Later boats of this era (about 2005 on) had what they called barrel portlights (curved to and bottom edges).

As a generality, all boats from about 2002 until about 2005 will have the windows I have.

The replacements have actually just arrived this morning, but I am just leaving for the weekend, so will post a photo early next week.

[tckearney]

Hi   I've just been down to the boat and my measurements are  630mm   x    120mm   x 10mm.   Oblong with rounded edges.   If these are what you have and you UK based Ill have five from you.

[tckearney]

whilw we are on this subject can anybody advise how you remove the tinted polycarbonate plastic from the cabin top skylights.  I cant fine any screws so Im assuming ist some sort of sealer holding it all together. 

[IslandAlchemy]

Hi   I've just been down to the boat and my measurements are  630mm   x    120mm   x 10mm.   Oblong with rounded edges.   If these are what you have and you UK based Ill have five from you.

They are actually 630 x 130 x 10.  I will post a photo later.  The ones I have had made have lugs on, so you can remove the hinges and catches from the frame and bolt the new windows in, but I guess you can cut the lugs off if you want to try to transfer those bits over to the new windows.

[tckearney]

not sure what you mean about the lugs. I will await the pics and double check the 120/130 measurement

[IslandAlchemy]

Here's a photo, and also a photo of the original unit.

I guess that if you wanted to transfer the hinges from the old windows, you would have to cut out where the holes are to make the big lugs into forks.

I will be fitting them next week, so will show post a photo or two of fitting them and what they look like when done.

[tckearney]

Hi Thanks but they are totally different.  Mine are just oblong with rounded corners, no lugs and are 630 x120 x10.  Ive just been to check

[IslandAlchemy]

It's a good job you checked.

[Salty]

whilw we are on this subject can anybody advise how you remove the tinted polycarbonate plastic from the cabin top skylights.  I cant fine any screws so Im assuming ist some sort of sealer holding it all together.

A couple of years back I wrote an article about “Crazed Portlights and Hatches.”  If you go to that article which was under Modifications and Equipment, and go down to “The first DIY bit” you have an explanation of how the hatches were taken apart.

[IslandAlchemy]

Following on from the initial post, I have just replaced the first lens, and it fits perfectly, doesn't leak, and I'm really pleased with the way it looks.

As said before, these are to replace the old lenses but these are fixed lenses (they do not open).  If anyone is interested, I have 14 of these extra (I had to buy a whole sheet of material), and I can provide them with screws, caps, and some fitting instructions at £40 each, which is about 1/4 of the Lewmar price.

[IslandAlchemy]

Just a quick update on this.

10 of the spare windows are now sold, so I now only have 4 left.