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Replacing leaking windows on a Catalina 30 requires removing the old port light, widening the fiberglass cutout, and sealing the hull layers to prevent water intrusion into the core. After removing a corroded, non-opening port light, the owner used a rotary tool with a diamond-coated cutoff wheel to enlarge the opening by approximately half an inch to accommodate a new, fully opening replacement unit.12:51 To ensure a watertight seal, the installation process involves applying butyl tape around the perimeter of the frame and sandwiching the hull between the interior and exterior frame sections.18:53 The owner also applied bathroom-grade caulking to the exposed edges of the hull layers to prevent water from wicking into the fiberglass core, a common issue on this model.17:08 A final test during heavy rain confirmed the new installation remained dry.23:42 Adding opening port lights significantly improves cabin ventilation compared to the original sliding windows.25:23

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