Islander 36 - Beckson Opening Port Installation

With our boats getting to be 25 - 30 years old, the original opening ports are getting a bit tired - maybe crazed, maybe leaking or maybe just looking old. Original construction differed in the number of opening ports. Some had only two - in the head and directly across from the head. Others had four or six, adding them fore and aft of the original two.

Early in 2005, Noble Brown coordinated a fleet purchase of Beckson opening ports. Five members ordered a total of 28 ports - at a delightful price of about $60 each.

Here is a pictoral description of the replacement of the old ports aboard Vanishing Animal.

P.S. In September 2022 we replaced the lenses on our 4 ports which had become cloudy over 17 years. We also replaced one gasket and one screen. From Defender Industries catalog: Lens: $60 each; Screen $20 each; Gasket $11 each.

The first step is to remove the old ports. Usually they have to be literly "broken" out.	The new ports come with a wide flange...	and a trim ring.
On our boat the cabin wall had delaminated...	so it was filled with epoxy and clamped.	Not perfectly pretty, but now solid.
Sandy holds the trim ring in place to mark the new outline.	Holes drilled for the rain drip spouts.	Cutting out the new outline.
A Dremel with a drum sander...	makes a nice smooth cut.	The opening is ready for the next step.
Holes are drilled from the inside for the 10 bolts (3/16).	Sandy then holds the trim ring to drill its holes.	Holes enlarged to 17/64 in trim ring.
Barrel nuts then fit (outside hold are counter-bored too.)	If you want flush ports, cut off the excess flange.	Wet sanding to smooth the edges.
Sandy removes the inside to access the holes.	Our workbench.	Probably should have done this ashore!
Inserted and buttered with lots of silicon II.	The trim ring squeezes out the excess.	Looking good inside.
Starboard side ...	and head.	Let it set up for 24 hours.
Ready to trim.	A razor worked well.	Almost cleaned up.
Ready for the water test.	So far, so good.	It stayed dry inside!
Very satisfied.	Looks good outside too.	Did the varnish for good measure!