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Yesterday I finished re-attaching the Rutgerson portlight - see images attached below.

I bought a warehouse leftover piece of clear UV protected 8mm polycarbonate sheet and cut out a much better fitting window panel into the stainless frame. Pro tip: use a small tooth jigsaw blade to cut the sheet in order not to chip the edges of the cut. I used a new metal blade and it worked perfectly.

I then used black Sikaflex to glue the panel to the stainless frame and then white Sikaflex to glue the portlight back in its mounting hole. Note: the original Rutgerson frame has two fixtures for the window panel, the outer Sikaflex seal and an inner molded rubber lip onto which the window panel seals. If you decide to replace your window sheet, then spare the rubber seal and do not mix it up with the identical looking Sikaflex mass.

The result is ... crystal clear :D The window is better than before. I decided not to go for butyl tape as the gap between the stainless window rim and hull is large and to my feeling large gap filling is not what butyl tape is good for.

With that, I conclude this topic!
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I've turned a few door around. Unscrew the door. Behind the hinges are 2 screw. There is also a screw inside the latch plate. Remove these and the frame will then push out (they are bedded in silicone). Simply turn the frame around and refit. Takes about half an hour.
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Bavaria Yacht Help! / Re: Warped cockpit locker lid
« Last post by SYJetzt on May 26 2024, 18:33 »
It looks as if the stop buffers under the lid are set much too high. If the lid is loaded, tensions build up on the vertical part and the result is the crack mentioned. The lid should rest on the bead in the hull  below along its entire length. Repairing it is complex because the vertical parts of the lid in the area of the crack have to be reinforced with laminate. To do this, the old laminate has to be sanded down from the inside and reduced in thickness. Enough laminate has to be built up to reach the original thickness again. Due to the high loads, I would recommend carbon rovings.
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Bavaria Yacht Help! / Throttle Lever Seal
« Last post by AMG on May 26 2024, 16:36 »
An alternative method to renew the throttle lever seal on a Bavaria 33 (2006) and other models, which does not require removal of throttle lever. Use neoprene roll, 8mm x 8mm, available from a well-known global website (£6.49 / 1.5 metres). Remove the old silicon first and clean with methylated spirit. Form a circle around the lever with the neoprene, and cut to approximate size. Check the final size of the circle and ‘mark’ and then make a final cut of the neoprene.

Note: it’s easier to join the neoprene at right angles with superglue. This will create a point in the neoprene circle, which you rotate to face downwards, out of sight.  Fix the neoprene circle in place with sealant or an adhesive of your choice (or both).   
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On another boat type, our Bavaria Cruiser 41, we intentionally made the aft head door to turn inside. I have noticed on many charter yachts the hinges have broken out, as the door sometimes (when not fastened properly) swings out fiercely during sailing with the original fitting swinging to the outside. For this type, frame profiles are still available from the factory and door is turned upside down to fit again. If this could work for your 2006 Cruiser needs some additional investigation. But with some TLC it would be possible.
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Bavaria Yacht Help! / Re: Warped cockpit locker lid
« Last post by IslandAlchemy on May 26 2024, 09:23 »
I've never seen anything like this before. Very strange.
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Scuttlebutt / Re: Anyone in Istria / Croatia with their boat?
« Last post by fremme on May 26 2024, 05:54 »
I'm located in Marina Novi, 40km south of Rijeka

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Modifications & Equipment / Remove / Turn / ReInstall interior door
« Last post by Talblitz on May 25 2024, 22:12 »
on some 42ft 2006 Cruisers the head door opens to the inside, towards the head. This works for skinny people only. The owners manual drawings show it opening to the outside, towards the saloon.

Anyone managed to remove the door without damage? Would love to turn it around.


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Bavaria Yacht Help! / Re: Warped cockpit locker lid
« Last post by JEN-et-ROSS on May 24 2024, 11:37 »
""Surely teak would shrink side to side (perpendicular to the grain) rather than lengthways?""

Dunno... But I really can't see any reason why it couldn't shrink lengthwise...
.........Bill..
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Bavaria Yacht Help! / Re: Warped cockpit locker lid
« Last post by tiger79 on May 24 2024, 11:26 »
Differential Shrinkage.......??
 Could the Mediterranean heat have dried out and shrunk the teak to such an extent that it's caused the GRP beneath to warp, (similar to a bimetallic strip)..??
Resulting in a stress fracture at the latch..??
   

Surely teak would shrink side to side (perpendicular to the grain) rather than lengthways?
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