PortlightsBuilding the portlights has been an interesting process. Earlier on 11-1-3 I described a way to construct the portholes. I proceeded on this approach to the point of constructing one porthole. I didn't like the result because:
My research into standard practices for building portholes revealed that I should cut a rabbet on the inside rim of the portlight to mount the glass and putty it in place. However the thickness of the cabin is only 3/8" thick which is the plan thickness. Bronze portlights are cost prohibitive and heavy. I could not find plastic elliptical portlights. I needed another way to fasten the glass in place that would keep it secure and allow easy removal in the future. Here follows what I did. |
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Here is the look I desired in the portlight - just a plain opening. |
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I started with this template. I needed a way of positioning holes in the glass and in the wood that would line up within a close tolerance. Here I drill holes in an oval that I just cut. |
I then clamp the template to the portlight opening. The sector holes are to help me line up and clamp it in place. I then drilled all the holes in the cabin side. |
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All the holes are drilled. I use 8 holes for the front and 6 for the sides. |
Here I've installed a screw. I used a 3/4" #10 brass slot head machine screw. I countersunk the screw so that the head is 1/16" below the surface. On the inside the screw forms a 7/16" high stud that will accept a nut to hold the glass in place. |
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Here is what the portlight will look like on the inside. Once the inside of the cabin is painted I will use either 3M 4200 or polysulphide or butyl to seal the edge and tighten the nuts down. |
For the side portlights the glass oval extends above and below the framework. I must trim this part off so it sits inside. As it turns out I must trim each one slightly differently. |
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Here is what the side portlight will look like from the inside. |
When it gets warmer, I will paste these holes over with thickened epoxy, sand, prime, and paint to completely hide the screw heads. |