Making the 8 portlight frames is a lot
easier with the use of a pattern. I decided to use 3/8" plywood to
give a little bit more substance to the frame instead of the 1/4" called
for. I screwed the ruff cut frame to the pattern and cut the edges back
with a flush cut router bit. Then I used a 1/4" round off bit. The
way I plan to put the parts together is shown in cross-section.
By turning over the frame I can cut a
rabbet into it to hold the lexan window using the same pattern.
The only thing I don't like about the frames
is the glue lines on the edges of the plywood. I am considering using
the same process with mahogany, but because of the bend of the front window
I am not sure if the mahogany would snap. (Note: I did try mahogany, but
the mahogany did not work well with the pattern - the router kept splintering
the wood).
Even though I had designed a sliding window
with the more rectangular style, I decided to make them as non-opening
portlights because I liked the oval style. I placed them foreword on the
cabin trunk to allow more light foreword and to allow some foreword visibility.
Here they are only being fitted to the
holes. I plan to epoxy the inside frame to the cabin trunk and to
use a bedding compound on the outside frame where the lexan window will
be installed. This will allow for replacement of the window if it
becomes damaged.
