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Installing a new Gebo portlight in the aft cabin of the 36-ft sailboat Athena requires modifying the cabin top to accommodate a sandwich of fiberglass, plywood, and a small air gap.5:04 Because the portlight frame cannot span the total thickness of the cabin structure, a router and a custom MDF template create a reveal, allowing the unit to seat properly.5:14 The installation uses butyl tape for a watertight seal, which the owner prefers over butyl-based caulk for its ease of removal and longevity.19:00

Separately, the project includes installing new deck fills for water, waste, and diesel.9:53 To protect the 18mm plywood deck core from water intrusion, the owner employs a drill-fill-drill method for smaller holes, filling them with thickened epoxy before redrilling to the final diameter.12:30 Larger holes are sealed by coating the exposed core with thickened epoxy.13:20 Additional interior work involves installing mahogany slats, applying interior finish 7070 paint, and insulating the hull with Armaflex AF foam to improve thermal efficiency.13:38

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