Forward Portlights Bedded and Sealed

After a bit of trial and error, trying to find the best method of installation, the Newfound Metals portlights have been installed and sealed in the forward salon.

While the installation videos on the NFM website well produced and informative, our installation is a bit different than “normal” and required a different technique. Different in that…

  • the cabin sides are nearly 1 1/2″ thick due to insulation (I suspect typical solid glass cabinside is about 1/4 inch)
  • I made the cutouts a bit smaller than recommended by NFM. Their template leaves about 1/4 inch gap around the perimeter of the portlight spigot, which I thought was a bit large. I reduced it to 1/8 gap and beveled the edges with a router.
Sealing involved three sizes of butyl tape: 1/2, 3/4 and 1 inch wide. I will put together a more detailed description of the installation when I get the pictures together.
In the meantime, here are the starboard side portlights fitted with scrap plastic laminate as a finish test to see how p-lam would look on the cabin sides.

Starboard portlights with sample p-lam finish.

The lights pass the “splash-with-a-bucket-of-water” test. Pressure washer weekend will be the ultimate test.

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