Newbie porthole question...

[Andy Kirkpatrick]

Hi, I want to remove some old glass windows and frames from a Hurley 22, use plywood and glass to cover the empty space, and add around 6 mm polycarbonate portholes instead, maybe with a stainless trim ring. Can I check I've got the steps correct:

1. Drill holes that match up between SS trim, polycarbonate and rebate.
2. Create a rebate inside the outer plywood (maybe the same size as the missing window, to add strength?).
3. Use Butyl tape to create a seal around the rebate.
4. Place the 6 mm round polycarbonate over Butyl tape, and then trim, and secure with 4mm SS countersunk hex socket machine screws (wrapping in Butly).
5. Tighten down by hand to avoid cracking.

Thanks for any advice.

Best

Andy

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[Tranona]

Hurley 22s have a number of different windows depending on who built the boat. If you have the smaller ones then just replacing them with polycarbonate either screwed on or through bolted using interscrews ia a sound approach. Not sure of the value of adding any plywood in to the mix, other than maybe framing the inside to allow better screw holding. Likewise a stainless surround is not structurally necessary and probably rather difficult to get made. Make sure you drill the screw holes oversize and countersink. Not sure about using machine screw - common to use raised head countersunk self tappers.