This article showcases the port replacement I did on our 1979 CS-36T. After much research I chose New Found Metals portlights. As always double click any image to see a larger and higher resolution version.
By letting the 3M 101 set up overnight it was pliable enough to remove with my chisel and yet still soft enough to get a clean edge with a solvent wipe down..
After The Paint Thinner
Here's the finished edge. I used paint thinner on a terry cloth rag to get that edge. DO NOT soak the rag in the solvent! You do not want the solvent to eat into or soften the sealant through transfer of of the liquid from the rag to the surface.
WARNING: You want just enough solvent to keep the rag damp, to smooth the outer edge of the sealant, that's all.
Tighten The Bolts
This photo shows the clamp still in place and the bolts inserted about two to three turns. At this point, if you have subscribed to my installation method, you may begin tightening the machine screws in an alternating pattern. If you subscribe to the NFM method of creating a "gasket" follow their instructions.
It's very important, for the seal, and even distribution of sealant under the trim ring, using either method, to tighten the machine screws so the trim ring compresses as evenly as possible.
I find it much easier to tighten until you have some resistance, then stop and wait and repeat. I would move onto another project and come back fifteen minutes later and take another few turns. Doing this allowed the butyl to compress more slowly and evenly than force tightening all the screws immediately.
You'll notice the Tef-Gel around the bolt head which made for easy turning with minimal grabbing of the two surfaces. Once done, I simply wiped this excess up with paint thinner.
The Final Result
Now that the ports are in I was finally able to remove the cover and snap a photo.
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