Fish Under Sail · video

What this video covers

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.

Boats in this video

More from Fish Under Sail

*Channel Update* - Big Things Coming, but First Going QuietSept 20268 Months of Hell — Splashing Sand Dollar at LastAug 2026Repairing a Crack in the Keel — This Had to WorkJul 2026Will the Engine Start? First Test after Hydrolock RebuildJul 2026

From Fish Under Sail — see the channel’s boat, crew, and every analysed video.

The Sailing Directory Newsletter

One email with the fleet's best finds — the moments, boats, and stories worth your watch time. Enter your own address to get your own copy.