John,
I replaced with the new style Lewmars. These are a much improved design
with only one frame seam (at mid bottom) and no through holes in the lens
for either hinges or closures. I tried the three in the aft stateroom
first and after those worked so well, I did the four in the salon the next
year.
Like you, I tried everything on the old ones, rebedding with butyl,
replacing the lens gaskets, replacing closing dog o-rings, carefully
recaulking the frame side seals. Even after all that work, they still
leaked. Grrrrr.
You can find the new ones online at less than $200 (e.g. Defender 1st
price). Replacing all seven was an expensive proposition but breaking the
project in two helped. But no more leaks (at least from the portlights) is
a worthwhile payoff, IMHO. Can't see that ever happening (at least on my
boat) with the originals.
Frank Ross
Beta Wave #206
Naples, FL 34102