Sailing SV Cordelia · video

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On a 42-year-old Venus 46 Ketch named SV Cordelia, Steve and Annette are mid-refit in the Rio Dulce, installing new foundmetal portlights to replace the original ones.0:21 The portlights arrived in the wrong size, requiring Steve to build wooden frames over each opening, router the holes to the correct diameter, and bevel the bolt holes so butyl tape seats into the surface as well as on it.9:53 Interior temperatures hit 37.8°C, making the two-pack primer Steve brought unsuitable; local advice led him to switch to a humidity-rated two-pack primer followed by a three-part two-pack topcoat, applied in five coats to the three porthole surrounds.11:58 A dust-collection frame taped over each opening kept debris out of the boat during drilling and routering.10:10 Quartz worktops are being fitted in the galley by a tradesman named Art, with a lift-up section preserved for future access to a second diesel tank.3:46 Upholsterer Neri, from Neary Upholstery in the Rio Dulce, dry-fitted new sofa cushions.1:12 A detailed how-to episode on the portlight installation is promised separately.15:29 Buying the wrong portlight size forces a significant remediation step — building up the opening with filler and custom frames before routing — that adds considerable time and material to what should be a straightforward replacement.15:47

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