[C320-list] Port Light Gasket Replacement

[Jeff Smith via C320-list]

Has anyone replaced the black gasket on a port light? If so, can you
provide the gasket size and any tips/instructions? We had 5” of rain in
Norfolk, and it all collected inside my boat. I changed the port light
o-rings (and horizontal frame caulk) before the rain, but it is still
leaking profusely. We are fairly certain it is the gasket.

Thanks,
Jeff
#121

[Brian McLamb via C320-list]

When I did mine it was a real educational experience. Lewmar has different
editions of their port lights. On my 2006 Catalina it turned out to be the
“New Standard” version of the Lewmar hatch. The gasket was 1 RE

Pack your patience when you do this replacement. I can truly say it was one
of the most frustrating and time consuming jobs I ever did on Serenity.
There is a very small lip on the frame that the gasket must be properly
fitted too. It is doable but don’t expect it to go as quickly as it appears
that it should be.

Serenity #1075
Brian McLamb

[Jack Brennan via C320-list]

Hi Jeff:

You're talking about the opening ports? I used rubber gaskets from Home Depot. They work better and cost maybe $8 or $10 instead of what, $50 or $60? The key is to trim the gaskets with scissors so they don't protrude above the metal edge.

Don't be so sure it's the gasket, though. I had one opening port with a persistent leak. It turned out the caulking went bad between the frame and the fiberglass. It wasn't a big deal to remove the frame and use butyl tape to recaulk, but it took me two tries to get it right. I had to position the frame just right to eliminate gaps.

Jack Brennan
Sonas, 1998 Catalina 320
Tierra Verde, Fl.

________________________________
From: C320-list <c320-lis...@lists.catalina320.com> on behalf of Jeff Smith via C320-list <c320...@lists.catalina320.com>
Sent: Saturday, September 20, 2025 6:51 PM
To: C320...@catalina320.com <C320...@catalina320.com>
Cc: Jeff Smith <svsailm...@gmail.com>
Subject: [C320-list] Port Light Gasket Replacement

[Ferris Wills via C320-list]

I ordered them from Catalina Direct, and I remember feeling that they cost too much 😂 Very important to pick all the old crude out of the groove in the frame and to cut and mate the new ones into that groove very carefully.

On the upside, no more leaky port lights!

Ferris Wills (Argo #505).

Typos by iPhone

> On Sep 20, 2025, at 4:05 PM, Brian McLamb via C320-list <c320...@lists.catalina320.com> wrote:
>
> When I did mine it was a real educational experience. Lewmar has different

[Leonard Hooks via C320-list]

Jack,
What did you buy at Lowes?


Leonard
#856

--
Leonard Hooks
A-1 Banner & Sign Co. Inc.
254-722-0775 cell

Soli Deo Gloria

[Jack Brennan via C320-list]

Hi Leonard:

I don't remember the brand name, but they were black rubber gaskets labeled for auto and marine use. Here is how I remember it. I'll double-check on Monday, when I'm at the boat again.

The gasket itself had three or four grooves. I trimmed the gasket so the sticky part was against the aluminum edge and the top groove was no higher than the aluminum edge. After cleaning the aluminum, I stuck the gasket and let it sit a while before closing the port.

The tricky part is cutting the gasket the proper length. Start a little long and then trim to where there is no gap.

I think the gaskets came in small, medium and large. I want to say I used medium, but can't be sure.

Jack Brennan
Sonas, 1998 Catalina 320
Tierra Verde, Fl.



________________________________

From: C320-list <c320-lis...@lists.catalina320.com> on behalf of Leonard Hooks via C320-list <c320...@lists.catalina320.com>
Sent: Saturday, September 20, 2025 7:37 PM
To: C320...@catalina320.com <C320...@catalina320.com>
Cc: Leonard Hooks <leh...@gmail.com>
Subject: Re: [C320-list] Port Light Gasket Replacement