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Replacing LEWMAR Portlight seals

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davewollin	Replacing LEWMAR Portlight seals		Lead	[-]
Posts: 39 06/28/08 11:56:26	Tags : None I am about to replace the portlight seals on my 10 year old C42. I have already exhausted all the other fixes including silicone grease and reversing the plexi. These helped for a while but the small leaks have started up again. I have the seals and am ready to go. Has anyone done this before? If so, please provide any tips you can that may make this easier. Any idea how long it takes to do one? Thanks Dave Wollin Summersault C42 MKII 605 Thanks, Dave Wollin Summersault 1998 C42 MKII # 605 Tri Cabin
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davidirvine		#1	[url]	[-]
Posts: 59 06/29/08 22:57:45	I replaced the seals on my boat having tried the other fixes that you mention. Guess what..they still leaked !! The solution in my case was to remove the complete portlight and re-bed . That did the trick. David #492
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Dave Bolding		#2	[url]	[-]
Posts: 46 07/02/08 09:44:49	Dave, I ordered the seals while away from the boat and talked to the Lewmar Rep. His recommendation was, before replacing the seals, remove the two blocks (2 allen screws) which the ports lock to and remove about 1/16" from the mounting surface. This will allow the port to seal tighter against the seals. We tried this and it does help. We no longer had leaks from the rain or from washing the boat. However they still leaked under heavy sea conditions. We did replace the seals eventually, just follow the directions. You will need a very small pick to remove all the old silicone. I also removed the port (just the glass) to make the replacement easier. Our leaks were not coming from the bedding. Have someone hold a hose on the ports to determine that the seals are were the ports are leaking. Dave Bolding, #462/2 cabin, Main Squeeze, Ventura CA
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davewollin		#3	[url]	[-]
Posts: 39 07/10/08 17:23:23	Dave B and David I, First of all thanks for your replies. The saga of portlight seal replacement. I have confirmed with a hose and tape that the leaks are from the seals not the bedding. I have replaced one seal so far. It took forever to get the old silicone sealer out and then a long time to dry fit the seal per directions. Once that was done I reset the seal in new silicone. I carefully checked every inch to make sure the seal was in the groove at corners and ends. It was pretty hard to close the port against the new seal, but it looked well seated. It took about 2 hours to so this: 30 seconds to remove the old seal, 45 minutes of scraping out the old silicone, an hour of pushing and rubbing with a plastic "pusher" ( the rounded handle end of a plastic serving spoon), 15 minutes to apply silicone to the groove and reset the new seal. I went to the next port and started the process according to directions. The seal refused to dry fit after about 90 minutes of struggling. I gave up! Put the old seal back and called it a day. This is no easy job. Five days later, it rains and Voila! portlight #1 still leaks! I repeated the hose test. It is not the bedding. It is not the o rings on the latches. It is not warped plastic. It is the brand new @#$%#^& seal! So I am starting from scratch. If anyone out there has a solution short of complete replacement. Please let me know. Dave Wollin Thanks, Dave Wollin Summersault 1998 C42 MKII # 605 Tri Cabin
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garrywillis		#4	[url]	[-]
Posts: 280 07/10/08 20:26:01 Moderator	Dave, These ports have always been a problem for Lewmar, Catalina and the various owners and this topic has been discussed many times in the past. I did a search in the archives and came up with this one that should fix your problem too as it may not be your seals that typically leak but other parts of your frame...specifically your frame joints. Give it a try. http://www.catalina42discussionforum.yuku.com/topic/555 Good luck, Garry "Breezn" #502 2-Cabin Last Edited By: garrywillis 07/10/08 20:28:43. Edited 1 time.
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symandalay		#5	[url]	[-]
Posts: 138 07/11/08 02:25:01	Put some silicone sealer on the exterior of the frame between the upper and lower frame halves. See if it still leaks next time it rains. That's the only thing I have had to do on my 1997. Colin Colin Mandalay Guide to Cruising here http://symandalay.googlepages.com/home
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davidirvine		#6	[url]	[-]
Posts: 59 07/11/08 13:59:27	Dave I tried every trick mentioned in the archives but until I removed the complete frame and re-bedded it, nothing worked. Curiously sometimes a hosepipe did not always reveal a leak in the way that steady light rain did. Good luck with this because it is not easy to fix. I doubt if the seal is ever the problem. Mine were as good as new when I removed them and in no case did replacing the seal solve anything. David 492
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snsusi		#7	[url]	[-]
Posts: 3 07/14/08 09:09:36	David 492, Like others, I've tried all the tips posted previously to no avail. I've decided to take the extreme step of replacing the existing portlights with new standard size 3 portlights from Lewmar ($345/ea from West Marine). How difficult was it to remove the original portlight frame? What sealant/adhesive did you use to rebed them with? Thanks, Patrick - Athena Hull #63
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