Portlights/Hatch Replacement

The survey showed that the deck hatches were leaking in places and two could not be securely closed as the handles were broken. The cockpit windscreen was badly corroded at it's base and the central (opening) windscreen was without glass. Although it was not unstable, it would need replacement in time. The perspex in the 8 portlights were crazed and the aluminium frames were discoloured and mild pithing on the surface. During the survey, the surveyor gently pushed on the heads portlight and the perspex fell out onto the ground below! The portlight over the galley actually fell out when we started to replace it!

DECK HATCHES

There were three deck hatches that were 500mm x 500mm in size with a 45 degree corner radii. The fourth deck hatch was 450mm x 320mm in size with a 45 degree corner radii. Again, an exhaustive Internet search revealed that the closest match were Gebo Deck Hatches and the keenest price was from Seateach in Emsworth. The old hatches were removed and much to my amazement, there was little or no sealent between the hatches and the deck. Once the screws were removed, the hatches just fell off. The new hatches were installed using a double line of black butyl rubber mastic 8mm wide strips. The hatches were placed in position and screwed down to the deck using new holes. The butyl rubber was used to seal over the old screw holes. Since fitting, there has been no water ingress through these new installations.

PORTLIGHTS

The portlights proved to be a bit more difficult to source. I found a US based website - http://www.semyan.com/wpblog/?page_id=69 where the author was doing much the same project that I was then contemplating. He had sourced the replacement stainless steel portlights from an American company - New Found Metals.

I contacted New Found Metals in the US and discovered that the portlights were made in China and would be posted from China to Ireland. When I factored in the costs of the initial purchase, freight, and the duty at the point of entry into the EU, it transpired that the portlights available on the HR-Parts web site were cheaper. I bought two directly from HR-Parts but soon discovered that Transworld Yachts in Southampton, the brokers from whom I bought "Forever" could supply them. I ordered the other six portlights through them in early December. They were to be shipped from Sweden on a new yacht being delivered to the UK, but it took over six weeks for them to finally find their way to Southampton. Storms, fog and appalling weather delayed their arrival. These new portlights were stainless steel and I ordered four that opened and four that did not. The opening ones were for the heads and the chart table (port side) and the galley and aft cabin (starboard side).

The old portlights proved somewhat stubborn to remove. They were fixed in place with an inner ring containing 14 bolts. All the top and side bolts were easily removed but the bottom row of bolts proved very difficult to remove. Most of them needed to be drilled out!

COCKPIT WINDSCREEN

The alloy windscreen frame had significant patches of corrosion at its point of attachment to the cockpit coaming. As a result there was some movement in the frame which was deemed unsafe. Much investigation of suitable alternatives naturally followed. After extensive Internet searches, I eventually found a company that had the capabilities to make on-off bespoke frames. I sent them many pictures of the windscreen with an exhaustive list of measurements. Eventually, the windscreen was made and delivered by courier to the yard. I anxiously assembled the windscreen from complicated looking diagrams but thankfully, it fitted perfectly and looked completely at home when it was finally installed.