Port light issues for sundancer 48

Chaika

New Member
Aug 16, 2018
3
Boat Info
2006 searay sundancer 48
Engines
Twin 540 Cummin v drives
the screw on the plastic dogs that lock the windows closed are corroding and snapping off. Sea ray tell me they don’t have parts to fix this and I need to buy new port lights at $750 each
Has any one tried drill the old screws out and re tapped the holes. Or has any one come up with a way to fix it with out replacing the port light it self
Thanks
 
As you can see some of the bolts have corroded and snapped off. Sea ray and the supplier Bimal say I have to replace the total window
Has to be a solution to fix it I would think
 

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As you can see some of the bolts have corroded and snapped off. Sea ray and the supplier Bimal say I have to replace the total window
Has to be a solution to fix it I would think
Sorry the supplier is Bomar
 
Take old bolts to good hardware store, make sure you go to stainless isle.
 
As you can see some of the bolts have corroded and snapped off. Sea ray and the supplier Bimal say I have to replace the total window
Has to be a solution to fix it I would think
I'm suspicious of the source of the corrosion. I think I'd remove the portlight, inspect/clean everything up, get all new screws, and re-seal/re-install.
 
Yes - a good hardware store will be able to help you source a new screw. Shouldn't be hard. All you need to do is get the same diameter and thread pitch - if the new one is too long, it can be cut. A small file and a nut, spun on the screw BEFORE cutting, are a good way to clean the cut threads.

And... check the outside caulking. It appears, from the pictures, like it hasn't seen any maintenance or attention, lately. The rust stains along the bottom appear to show water seeping between the inner hull and the portlight. HOWEVER, that also means that there is most likely water seeping down BETWEEN that inner, fiberglass liner and the outer hull.

Just out of curiosity, did you try contacting Pompanette/Bomar directly? A phone call is usually best, if you didn't already do that. If you have a good Sea Ray dealer near you, try the same thing with them. From your post, it sounds like you had contacted Sea Ray, the company. The company won't have small parts like that - just the whole assembly.
 
Yes - a good hardware store will be able to help you source a new screw. Shouldn't be hard. All you need to do is get the same diameter and thread pitch - if the new one is too long, it can be cut. A small file and a nut, spun on the screw BEFORE cutting, are a good way to clean the cut threads.

And... check the outside caulking. It appears, from the pictures, like it hasn't seen any maintenance or attention, lately. The rust stains along the bottom appear to show water seeping between the inner hull and the portlight. HOWEVER, that also means that there is most likely water seeping down BETWEEN that inner, fiberglass liner and the outer hull.
Your not suggesting he just caulk around the outside flange of the portlight are you?
 
Your not suggesting he just caulk around the outside flange of the portlight are you?
No. I actually wasn't specifically suggesting a way to fix - just that it looks like things are compromised on the outside, based on the internal seepage. I was really just "seconding" your suggestion. I agree with you that the correct way to fix it is to completely remove it. Anything else is really just a bandaid.
 
Had an ‘06 260DA with same black plastic dogs. I broke off the same screw. Mine broke flush, so there was nothing left to grab with vice grips, etc....It was SS and attempting an easy out was useless as well.

However, I did the research and found the black plastic dogs if you need them. Below is the contact info for replacements. This was a real pain to find....

upload_2018-8-17_12-51-5.png

Bennett
 
As you can see some of the bolts have corroded and snapped off. Sea ray and the supplier Bimal say I have to replace the total window
Has to be a solution to fix it I would think

So I have the same issue. Screw corroded and broke off flush with window bezel. There is no meat on the screw exposed so there is no way to back it out. I don't think tapping will work. the source of the corrosion on that bottom dog leg is salt water laying on the outside gasket seeping into the bottom which is the low point where that screw lands. I did some research and Bomar also indicated that you need to purchase an entire new Stainless frame. I ordered spare dog legs from them and found that at the end of the dog leg there is a set screw. Tightening the set screw pushed the window firmly into the gasket. When I saw this, I realized that the window is leaking at the gasket seal because these set screws weren't tight. I cleaned up everything and tigheted the dog leg on all four remaining. it hasn't leaked anymore all summer with out that bottom leg. I went around and tightened all the dog leg set screws and all frame screws. to my surprise a lot of them were very loose. When I refer to the dog leg set screw, it is the plastic screw at the tip and not the stainless mounting screw. if your not looking for it you wouldn't even know its there. I plan to remove the window in the off season and attempt to remove the rest of the screw...... I don't want to purchase a new frame. Hope this clarifies.
 
I'm suspicious of the source of the corrosion. I think I'd remove the portlight, inspect/clean everything up, get all new screws, and re-seal/re-install.

That’s what I would do.
 

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