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Catalina/Capri 25/250 Sailor's Forums

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measure twice, cut once, wrong?

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rclift
Navigator

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USA
152 Posts

Initially Posted - 03/05/2006 : 13:46:31

Here's a question for the fiberglass repairmen in the group. I was installing my new Lewmar port windows and measured, remeasured and then cut out the window only to find that I had held the saw at too steep an angle while making the cut. No matter how I place the windows there is going to be an 1/8 inch gap visible from the out side. It looks like I need to add back about a 1/4+ inch of material to fill that gap. What is the best way to accomplish this?

Ray Clift
Buzz 1361 sk/tr
Oregon

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Steve Milby
Past Commodore

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USA
5904 Posts

Response Posted - 03/05/2006 : 14:11:59

Some kitchen sinks are mounted with a stainless steel "beauty rim" around them, to trim between the sink and the opening. Maybe you could use the same idea for your ports. You could make a ring out of white sheet plastic, about 1/8 or 3/16" thick, that fits around the windows, and that overlaps the opening slightly. To give the rings a nice, smooth, finished look, you could round-over the outside edge with a router.

It would be a whole lot easier to cover the opening than to fill it in and match the color and finish.

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OJ
Master Marine Consultant

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USA
4382 Posts

Response Posted - 03/05/2006 : 16:27:44

I always thought it was "measure once, cut once and caulk the difference . . . !"

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rclift
Navigator

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USA
152 Posts

Response Posted - 03/05/2006 : 22:14:44

Thank you Steve for seeing an easier, more practical option to overcome this little dilemma.

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Ericson33
Admiral

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USA
892 Posts

Response Posted - 03/06/2006 : 00:00:07

I will make a fast reply and if you are interested I can go into more detail of how you can fix the problem with glass and resin. Remember that fiberglass is a very easy material to work with, and if you screw it up you can always grind it back out and try again. I would work from the inside of the cabin for this job, fist get a piece of formica material a little bigger tan the window cutout, then some cardboard and make a template of the size of the window, glue the cardboard onto the formica, wax the edges of the exposed formica, and tape the formica to the hull from the outside. Now you will apply the gelcoat first to match the hull, do about three thin layyers, or use the spray can that you can get, I will get the company name tomorrow. Then start laying up the glass and resin, Before this is done you will want to champher back the edges so you can build up the resin and glass. you can do three layers at a time, and this should only take a couple of hours. Once you get close to the inside edge you will again gelcoat a couple if layers matching the liner color. apply the gelcoat about a 16 of a inch outside the liner, then coat the inside with PVA. after it cures then lightly san the interior geloat, and remove the outer forica and cardboard. Do any touchup and you are finished. PM Me and I can give more detailed instructions and provide a photo if you have one.

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The Officers, Staff and members of this site only provide information based upon the concept that anyone utilizing this information does so at their own risk and holds harmless all contributors to this site.