(09-14-2022, 02:20 PM)hiccup Wrote: I know I'm late here, but figured the following would be useful for someone, at some point.

2001 3800

I decided to replace all 6 portlights.

-Remove interior screws.  Some are difficult to access and a 90 degree screwdriver can come in handy.
-Remove the interior half of the clamshell.  I found the best way was to open the window and grab it with two hands and pull/rock it back and forth to break the sealant (Tiara used silicone) bond.
-This will expose the bent over tabs screwed to the interior of the boat that holds on the external frame/clamshell.  The tabs are underneath the vinyl liner and they were likely installed before the vinyl was.  You will have to stretch the vinyl to get to all the screws but it isn't too bad.  Once the screws are out, bend the tabs so they clear the hole.
-Getting the frame out was tough.  I used a heat gun to soften the adhesive a bit and carefully used shims around the outside lip to pull the frame away from the boat.  The danger here is damaging the gel coat.

I removed all the exposed balsa in the window cutout with a chisel and backfilled with thickened epoxy.  Fortunately it was all dry.

To put the new windows in was straightforward with the exception of getting the external frame in.  I ended up using a bunch of small trigger clamps to get the external frame to completely seat in the opening.