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FITTING INSTRUCTIONS

Cut-out sizes, deck preparation, bedding, screw selection by skin thickness, trim fitting, valance types and seal replacement for Lewmar Standard opening portlights and fixedlights.

DocumentLewmar Standard Portlight & Fixedlight Fitting Instructions
FormatPDF · 2 pages · 0.1 MB
LanguageEnglish
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Fitting InstructionsPDF · 2 p.Seal replacement instructionsPDF · 2 p.Seal replacement instructions (German)PDF · 2 p.Valance types and fasteningsPDF · 1 p. Old Standard portlight seal replacement (B5963)PDF · 3 p.
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Cut-Out SizesFittingValance TypesSeal ReplacementProducts
Lewmar Standard Portlight & Fixedlight — Fitting Instructions

Cut-Out Sizes

Size No. Product size Dim A mm Dim A ins Dim B mm Dim B ins
0 4x10 156 6⅛ 303 12
1 5x12 171 6¾ 347 13⅝
2 4x14 156 6⅛ 405 16
3 5x15 171 6¾ 429 16¾
4 5x23 171 6¾ 627 24½
5 7x15 244 9⅝ 429 16⅞
6 3x15 126 5 429 16⅞

Corner radius R52 typical. Compliance: ISO/DIS 12216.2(E), design category "A", areas II, III and IV for portlights and I, II, III and IV for fixedlights; any modification invalidates it.

Preparing the Opening

  • Flat surface, max tolerance +/-1mm, extending 12mm beyond the planned cut-out; deck/hull thickness 6-34mm.
  • Hold the inner frame inside the intended position to check a flat bearing area and room for the trim; mark the cut-out with a pencil.
  • Hull area I: the lower edge at least 600mm above the flotation plane, fully loaded, upright at rest. For ocean or offshore use, nothing may stand proud of the hull outer surface or integral fairing.
  • Prepare a template when fitting several; the outer frame must sit squarely on the opening.
  • Seal exposed composite laminate; deburr metal decks. Portlights are not stiffening members: stiffen the deck.

Bedding and Fixing

  • Measure skin thickness (plus inner trim if fitted) and choose the screw from the table: the M5 screws supplied suit 17-22mm only.
  • Bedding compound in the outer-frame channel: good adhesion (e.g. silicone), marine grade, 3mm minimum thick and compressible.
  • Inner frame joint on the lower edge; bolt from the centre out to the ends, max torque 2.8Nm (25 in.lb). Clean off surplus.
  • Trim length H = T - 12mm: cut the inner edge only (fine saw or tin snips) and snap it onto the inner frame all round.
  • Check window operation, locking and even seal pressure; leave the flyscreen on board.
Order No. Dimension T Screw
19899000 6 - 9mm use M5x12 View part →
19899100 8 - 13mm use M5x16 View part →
19899200 12 - 17mm use M5x20 View part →
19899300 17 - 22mm use M5x25 Ask us to source it →
19899400 22 - 27mm use M5x30 View part →
19899500 27 - 32mm use M5x35 View part →
19899600 32 - 34mm use M5x40 Ask us to source it →

New Standard Portlight Valance Types

Valance Fastening Deck thickness Supplied with port
AF M5 X 12
M5 X 16		 8.5 TO 11mm
9 TO 13.5mm		 NO
YES
AL M5 X 12
M5 X 16		 5.5 TO 8mm
6 TO 10.5mm		 NO
YES
AS (8.5mm) M5 X 16
M5 X 20		 14 TO 17mm
15 TO 19mm		 NO
YES
AV (11.5mm) M5 X 20
M5 X 25		 17 TO 21mm
20 TO 22mm		 YES
NO

Deck range per valance from the drawing: AF 8.5 to 13.5, AL 5.5 to 10.5, AS 14 to 19, AV 17 to 22 (mm). Not to scale.

Seal Replacement and Care

  • Check the new seal is the right size (the fitted seal is slightly stretched at the corners).
  • Pull out the old seal; it hooks into a cavity in the frame and is bedded in silicone. Clean the cavity with a plastic scraper, corners especially; no solvents (they attack the anodising and the acrylic).
  • Dry fit: seal joint and air release holes positioned relative to hinges and handle catch as in Figure 2. Push home from the middle of each edge towards the corners: hinge edge first, then the handle edge (Size 5 with handles on three edges: the edge opposite the hinge), then the rest. Use a pusher or roller tool at the corners.
  • Inspect open and closed, inside and out; an uneven area means it is not seated. Remove it, run a bead of silicone round the cavity, refit, close the portlight and leave 24 hours.
  • Then apply a very thin coat of silicone grease on the hinge edge of the seal where the window slides across it.
  • Wash with soap, water and a soft cloth; never abrasive or solvent cleaners on the acrylic.
  • Deadlight: make a notched plywood, aluminium or GRP plate; remove the trim and drill and tap the inner frame to bolt it on.

Need a part that isn't listed? Ask us to source it and quote the part number from the PDF.

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