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Catalina/Capri 25/250 Sailor's Forums

Catalina 250 Specific Forum

Cockpit PortLight install

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DavidCrosby
Navigator

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USA
233 Posts

Initially Posted - 03/29/2022 : 19:36:52

My big project for this year is the addition of cockpit portlights. I hit the jackpot. I found a pair of brand new Lewmar Opening PortLights on Sailing Anarchy. They were originally bought for a Catalina 30 about 10 years ago and were never installed. These things sell for about $350 each. I got two including shipping for $350. They were still in their original packaging.

These are size #3.
Exterior = 7 1/2" x 17 11/16"
Cut Out = 6 3/4" x 16 3/4"

I feel that this is the maximum size that can be installed in the C250wk. The C250wb cockpit height is lower than the C250wk and there is a bend in the wall just above the window top. If the C250wb has the bend at the same place they may not fit flush in a C250wb.

Here is a photo journal of the install process.

1st I made a female template out of a piece of plywood to make sure that the portlight would fit within the hole.

I then checked the fit:

And checked again - this time with the interior mounting frame in place:

Next, I cut a piece of Luan to create a male template. This is the actual cutting guide. I checked to see how it fit within the female template:

In this photo I am taking measurements to make sure the window is level.

The exterior dimension template is taped in place. Note that I drilled two small holes through the interior and exterior templates, so that I could check fit inside the cabin.

Here is the template in place inside.

The interior template then went back outside for marking of the cut line. Not shown, I took the exterior template and checked it on the inside of the cabin to make sure that the frame overlap was not going to hit anything (curvature of the liner, etc.).

I then taped a box to the inside of the cabin cut area to collect the dust and debris.

Using a 3.5in hole saw I cut the four corners. I then used a vibrating saw to cut the straight lines.

Here is a view of my trial fit.

Next are two views of the finished product:

And, for the final picture. This is what I really like about our boats. While I would love to have a Catalina 310, I can bring my Catalina 250 home. Park it in the driveway and work on it where all of my tools are at. And in a few months pack it up again to drive north for a vacation on Lake Superior.

David Crosby "Small World"
'02 C250 WK #614

zeil
Master Marine Consultant

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Canada
1311 Posts

Response Posted - 04/02/2022 : 09:35:04

Wow... David thank you for sharing this great modification. Having installed the 5" fixed round port lights, I'm just a little envious of your professional installation which provides even more light and certainly the ability to have greater air circulating in the aft berth area. Besides, it enhances the look and increases the functionality of an already wonderful boat.

Henk & Johanna
"Floating", a few off your "barnacles".
"Someday Lady" '95 C250WB #151 ('03 - 2016)
"Sea ya" 30ft Bayliner (04-2018 - 09-2018)
"Mariah" '96 C250WB #191 (05-2019 - 15-05-2023)
"Lady J" '00 C250WK #499 (05-2021 - 09-2022)

Edited by - zeil on 04/02/2022 09:36:02

Commodore
Russ Johnson

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USA
695 Posts

Response Posted - 04/17/2022 : 18:04:35

David,

I would like to submit your project the the Mainsheet quarterly magazine.
Please contact me if you are interested.

Thanks, Russ

Russ Johnson, Commodore 2009-2024 (commodore at catalina-capri-25s.org)

Commodore
Russ Johnson

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USA
695 Posts

Response Posted - 08/16/2022 : 07:54:17

David,

Thank you for submitting your portlight article.
It has been published in the 2022 Mainsheet Fall edition on pages 18,19, and 20.

Fair winds, Russ Johnson
Commodore

Russ Johnson, Commodore 2009-2024 (commodore at catalina-capri-25s.org)

Edited by - Commodore on 08/16/2022 07:55:11

Voyager
Master Marine Consultant

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USA
5320 Posts

Response Posted - 08/16/2022 : 16:21:27

David, you did the group proud. Nice work!

Bruce Ross
Passage ~ SR-FK ~ C25 #5032

Port Captain � Milford, CT

k3fuller
1st Mate

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USA
82 Posts

Response Posted - 08/17/2022 : 12:19:03

Indeed, looks great!!!

2004 250WB #781

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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.