Port light issues for sundancer 48

Discussion in 'General Discussion' started by Chaika, Aug 16, 2018.

  1. Chaika

    Chaika New Member

    3
    Aug 16, 2018
    2006 searay sundancer 48
    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
     
  2. Little Ducky

    Little Ducky Well-Known Member

    Jun 5, 2017
    Chattanooga TN/Dickson TN
    1998 SeaRay 290 Sundancer
    Twin EFI 5.0L w/Alpha 1 drives
    Please post up a picture of the port light.
     
  3. Chaika

    Chaika New Member

    3
    Aug 16, 2018
    2006 searay sundancer 48
    Twin 540 Cummin v drives
    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
     

    Attached Files:

  4. Chaika

    Chaika New Member

    3
    Aug 16, 2018
    2006 searay sundancer 48
    Twin 540 Cummin v drives
    Sorry the supplier is Bomar
     
  5. bahamabreisus

    bahamabreisus Well-Known Member

    Oct 25, 2007
    Hampstead NC
    500 dancer, previous 420,390,300 dancers
    detriot 8v92
    Take old bolts to good hardware store, make sure you go to stainless isle.
     
  6. Woody

    Woody Well-Known Member

    Nov 20, 2007
    N. Wisconsin/Lk Superior
    2005 420DA
    Cummins 6CTA8.3
    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.
     
    JVM225 likes this.
  7. Lazy Daze

    Lazy Daze Well-Known Member TECHNICAL Contributor

    Apr 21, 2009
    PA
    Various
    Various
    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.
     
  8. Woody

    Woody Well-Known Member

    Nov 20, 2007
    N. Wisconsin/Lk Superior
    2005 420DA
    Cummins 6CTA8.3
    Your not suggesting he just caulk around the outside flange of the portlight are you?
     
  9. Lazy Daze

    Lazy Daze Well-Known Member TECHNICAL Contributor

    Apr 21, 2009
    PA
    Various
    Various
    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.
     
    Woody likes this.
  10. bbwhitejr

    bbwhitejr Well-Known Member

    Apr 14, 2013
    Lake Lanier GA
    2007 44DB
    Cummins QSC 8.3s
    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
     
  11. Rocket

    Rocket Member GOLD Sponsor

    549
    Jan 14, 2008
    Long Island NY
    2007 48 Sundancer
    Previous: 2004 420DA, 2007 320DA, 2006 240DA
    Cummins QSC 540 8.3
    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.
     
  12. JVM225

    JVM225 Well-Known Member

    Apr 8, 2008
    Farmingdale, NY
    2002 410 Sundancer, Monaco Edition.
    3126 Cats.
    That’s what I would do.
     

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