Saturday, July 12, 2014

Portlights are finally set in place

Way back, almost a year ago August I went about glassing in place the double thick backerboards for the later to be installed portlights from Newfound Metal.  I hadn't even purchased them yet.  They sent me a template drawing, which I used to lay out and accurately place the backer boards.

In January I recieved the portlights ... 10 of them ... six 7 x 15 inch and four 5 x 12 inch.  So, they just sat in the boxes until this week.

After watching their installation video several times and reading the installation instructions, I developed the best way to lay out and set mine in place.  Not having the metal template, which for a rental fee you can borrow from them, I developed my own way to use the beauty ring as a template by making points on bolts, drilling one index hole, then BANGING the other points to make drill marks.


After drilling small holes I set the ring on the cabin side and traced out the pattern.  Next, using a die grinder with a burr for the corners and 4-1/2 inch angle grinder with a diamond blade for the straight sections.



After I had cut a smooth surface on the fiberglass I used a router bit ... a very long router bit, with bearings at both ends of the cutting blades, to route out the wood from the backer boards.



Next, I fit in the Portlights.  Aren't they purrrrdy ???
 

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