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Resealing 43-year-old portholes, pilothouse windows, and hatches requires removing and reinstalling over 500 corroded stainless steel screws from aluminum frames. To prevent future galvanic corrosion, apply Tef-Gel to all fasteners during reinstallation. When removing seized screws from aluminum, use an impact driver to avoid drilling out hardware. The process involves cleaning the frames, applying butyl tape to the outer edge, and carefully aligning the window against the hull to ensure a watertight seal. Because replacement windows for older vessels can cost upwards of $15,000, salvaging and refurbishing components from a donor boat often provides the only viable path for repair. Tinting windows with 5% film helps manage cabin temperatures in high-heat climates. The project frequently encounters setbacks, including mismatched window dimensions, snapped rivets, and severely corroded hardware that necessitates combining parts from multiple units to create functional assemblies. Success depends on methodical cleaning and the careful application of butyl tape to avoid premature adhesion during the delicate mounting process.

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