Gary, welcome. I am sure you'll find helpful commenters in the forum here who can share their experiences to everyone's benefit.

I just checked through our Technical-Upgrades and Technical-Maintenance libraries and could find no articles on the replacement of these portlights. That's a great opportunity for a talented person to take copious photos as they proceed through their project and (with our assistance, if desired) to do a write-up for JibSheet and for our archives. Please keep us in mind as you go forward on this replacement project.

Welcome, Gary. My boat is a MK I, so I don't have that aft fixed port, however you might check Catalina Direct, here's a link to the their "Ports" page.

[url]http://www.catalinadirect.com/index.cfm?currentpage=1&fuseaction=categor...

If you just need the correct sized Lexan to replace just the lens, try Select Plastics. [url]http://www.selectplastics.com[/url]

The owner, Tony, is a great guy and is very helpful. Good Luck & enjoy your new 36.

Mike

[QUOTE=Gsmith;8091]Hello, we are in the process of finalizing the purchase of a 1993 MkI. In the survey a hairline crack was found in the portside aft fixed cabinside portlight. Has anyone had experience replacing these and or advice on sourcing the part, my search didn't turn up anything. By the way your association and this web site were a major influence on our decision to pursue the C36. Once we close the sale I look forward to a membership and all the expereince and benefits that it brings.

Thanks

Gary S[/QUOTE]

Interesting, I bought a 1993 Catalina 36 in January. My portside aft fixed port over the galley started leaking after Irene blew thru in Oriental, NC.

What did you find out in fixing your leaks that you might share with me since I now need to deal with the same issue you did?:confused:

Looks like the recommended installation involves Dow 795 & 3M black foam tape as a spacer. Did you find the same? Did you replace your plastic?

I found this document somewhere....:confused:, but not sure if it applies....looks like it applies to ports (without aluminum frames) like the ones we have...

So my port deadlight (fixed portlight) started leaking on my 1999 Catalina 36 MkII, and I started the disassembly today. Interesting construction...
Can't believe this construction remained watertight for 10 years! I wouldn't give this - two halves with gasket in between - construction more than one year...

Anyway. Question is, is there still interest in a detailed description of construction and replacement of these windows?

I also think there's a quick fix possible for mild leaks; when you replace the gaskets by silicone based sealant. I'm going to try that on the other two fixed portlights in the hull. Saves $ 250 each, if that works....

Martien.
S/Y 'EASY'
#1739
Monnickendam - The Netherlands

I'd like to see pics of the process. I'm going to have to have mine re-glazed as they're starting to craze. Select Plastics can rebuild them, which is good.

Are your ports the 'new' or 'old' style Lewmar ports? It looks like your cutout has larger radii at the corners than my old style ports have.

'EASY' has old style - what appear to be Lewmar size 2 - fixed portlights. Only after searching the internet, I found that a lot of Catalina 36 MkII have the more rounded RE-type portlights (as seen in attached picture).

Now the cut-out size of the hole does not exactly match the Lewmar size 2; nor does the original show any "Lewmar" markings. But I figured that it would be Lewmar, since all other hatches and portlights are Lewmar....

Does anybody know what brand/type/size has been fitted in 1999?

By the way, the window is very difficult to remove without damaging either frame or boat. I tried to cut the sealant with a knife (don't!). Tried a stainless steel wire (between window flange and boat hull a bit like [URL="http://www.eckersleys.com.au/site/assets/media/images/products/Phase-3/S..."]this[/URL]) as a cutting tool. But ended up with destructive removal, since I was going to renew it anyway.

So, don't keep us guessing... What is the 'quick fix' solution you thought of for mild leaks?

I was going to wait until I had some pictures, but if you remove the two (degrading) gaskets on each side, that create the leak path, it would be easy to fill the gap with a sealant. I think it's possible to make it look at least half decent and will hold for a few years.

Of course if the sealant starts to leak, it will be very difficult to remove aand re-seal the porthole.

Without pictures I find it very hard to explain and our Queen's abdication and Kings coronation sort of distract me from the repairs today.....:)

Hi

I make replacements for the large trapezoid fixed lights over the galley and nav station. I have templates for the later MK1 C34/36 (same for both boats). I will be making new lights for my MK2 in the next couple of weeks. I also make replacement lights for the 4 opening Lewmar portlights on the C36 (6 on the C34). I can make them in the traditional bronze but have been doing a lot of them in a light-medium blue that is closer to the color the Lewmar opening portlights were that look really nice.

I will attach a link to pictures (hi res) rather than put low res on this website.

I would like to know everything you learned while removing/repairing the deadlights below the rubrail.

Thanks,

Mark

Here is the link to pics of the new fixed lights installed (blue):

[url]https://picasaweb.google.com/110180214793263976451/NewWindowsIn87C34#[/url]

I will add some pics of the opening portlights with new blue lenses soon.

OK, learnings from resealing/caulking the 'old style' Lewmar fixed portlights. What I referred to as the [I]quick fix[/I] earlier, including the pictures on my [URL="http://blog.taas.it/2013/05/for-catalina-36-ia-community.html"]blog[/URL].

It might be a bit a bit heavy on the details for such a minor repair. But somebody here asked for everything I learned below the rubrail... :)

Ascension weekend seems an opportunity to replace that removed portlight...

My boat, 1993 Mk I, was less than a year old when the fixed ports started leaking. I tried several types of compound to re bed but nothing worked. To tighten the seal I decided not to rely on glue sealant and went mechanical. The old bedding material makes a wonderful sealing medium, just like a rubber washer on a bolt .
I created fasterners for the ports with Stainless Pan head screws (stove bolts) with stainless grommet type washers on the outside of port and on the inside of the cabin a washer, lock washer and acorn nut. The end result looks professional and sharp and 20yrs later hasn't leaked a drop. It looks like that was the way it was intended.
It is really important to set the fasteners close together as consistently as possible, the fasteners if I recall are less than 2" 2.5" a part. Fortunately I had the help of my father in law at the time who is an engineer and particular about measuring.
I will post a photo when I get down to the boat this afternoon.

Hey Taas;
Great instructive text and pics on your blog!

Don't be afraid to submit technical articles in the future!