Bomar portlights are engineered for durability, clarity, and watertight performance in marine environments. Designed for a wide range of vessels—from luxury yachts to commercial workboats—these portlights are trusted by boat builders and marine professionals worldwide. This article provides a detailed overview of the technical specifications, installation process, and key considerations when installing Bomar portlights, based exclusively on the provided documentation.
Technical Specifications and Design Features
Bomar portlights are manufactured in the United States using marine-grade materials such as stainless steel, aluminum, acrylic, and molded components. These materials are selected to ensure performance in harsh marine environments, including resistance to corrosion, UV exposure, and extreme weather conditions. The portlights are available in multiple shapes, finishes, and sizes to accommodate different hull designs and aesthetic preferences.
One of the distinguishing features of Bomar portlights is their precision engineering. The portlights are designed to fit securely into the deck while allowing for smooth operation and reliable sealing. The documentation specifies that portlights require specific fastenings depending on the thickness of the deck. If the fastenings supplied with the portlight do not suit the deck thickness, additional fastenings must be ordered separately to ensure proper installation.
The portlights are fitted by clamping the outer frame against the deck using the inner frame inside the boat. The installation process includes a test fit to ensure the portlight aligns correctly before applying sealant. This step helps prevent misalignment and potential water intrusion.
Installation Process
The installation of Bomar portlights requires careful planning and execution to ensure a secure and watertight fit. The following steps summarize the key phases of the installation process as detailed in the documentation:
1. Preparation and Marking
The first step involves preparing the installation site. A template is provided with the portlight, which should be cut out and placed over the back of the portlight to verify its dimensions. The template is then taped to the boat to mark the cut line. It is crucial to ensure the surface is flat and within a tolerance of ±1 mm to avoid installation complications.
During this phase, users are advised to take care to avoid cutting near power cables, gas pipes, or other services. The use of appropriate safety equipment such as safety glasses and electrical power breakers is emphasized.
2. Cutting and Drilling
After marking the cut line, a hole is drilled on the waste side of the cut line to accommodate the jigsaw blade. The jigsaw is then used to cut the aperture through the boat. In some cases, it may be necessary to remove or modify the headlining to complete the cut.
3. Test Fit
Before applying sealant, the portlight should be test-fitted to ensure proper alignment. The outer frame is clamped against the deck using the inner frame inside the boat. The clamp ring is also tested during this phase to ensure it functions correctly.
If the portlight is replacing an existing one, any old fixing holes should be filled with sealant to prevent leaks. This step is particularly important when the new portlight has different dimensions or mounting requirements.
4. Bedding and Sealing
Once the test fit is successful, a generous bead of bedding compound is applied around the frame where it makes contact with the deck. The portlight is then refitted to the boat. A small amount of bedding compound should extrude from the gap between the frame and the deck, ensuring a watertight seal.
The outer frame is clamped to the inner frame using the provided fixings. It is important to grease the fixing threads to prevent corrosion and ensure smooth operation. After clamping, the excess bedding compound is cleaned up to complete the installation.
5. Final Adjustments
After installation, it is recommended to avoid opening and closing the portlight excessively until the lower frame is securely mounted to the deck. Portlights may be fitted to decks of varying thicknesses, but on thinner decks, the flange in the lower frame may intrude into the cabin. If a Trimkit is being used, the size of the hole cut out in the boat must be increased by 3 mm to accommodate the additional hardware.
When opening the hatch lid, it should be moved past 90 degrees to allow for proper fastening to the deck. If an obstruction prevents the hatch from opening fully, it may not be possible to install it correctly. Additionally, when the hatch is fully open, the lid should rest supported near the edge with the handles. If the lid is supported near the hinges, the leverage on the lid may cause damage to the hatch.
Key Considerations for Installation
Several factors must be considered during the installation process to ensure optimal performance and longevity of the portlight:
Deck Thickness
Portlights are designed to be installed on decks of varying thicknesses. However, the documentation notes that portlights fitted to hulls approaching the maximum deck thickness may experience restricted opening. This limitation should be taken into account when selecting the appropriate portlight for a given vessel.
Fastening Requirements
The documentation specifies that different fastenings may be required depending on the deck thickness. If the fastenings supplied with the portlight do not suit the hull, additional fastenings must be ordered separately to ensure a secure fit. This requirement highlights the importance of precise planning and measurement during the installation process.
Sealant Application
Sealant application is a critical step in the installation process. It is recommended to apply a generous bead of bedding compound around the frame to ensure a watertight seal. After refitting the portlight, a small amount of bedding compound should extrude from the gap between the frame and the deck, indicating a proper seal. Any excess compound should be cleaned up to avoid interference with the portlight's operation.
Thread Greasing
To prevent corrosion and ensure smooth operation, it is important to grease the fixing threads during installation. This step helps maintain the integrity of the fastenings and reduces the likelihood of future issues related to rust or wear.
Maintenance and Longevity
While the primary focus of this documentation is the installation process, it is important to consider the long-term maintenance of Bomar portlights. Regular inspections should be conducted to ensure that the sealant remains intact and that there are no signs of corrosion or wear on the fastenings. If any damage is detected, repairs or replacements should be carried out promptly to maintain the performance and safety of the portlight.
The documentation also mentions that Bomar portlights are designed to be serviceable, which means that certain components can be replaced or adjusted as needed. This feature is particularly valuable for marine professionals who require reliable and durable equipment for their vessels.
Conclusion
Bomar portlights are engineered to meet the high demands of marine environments, offering clarity, style, and watertight performance. The installation process requires careful planning, precise execution, and attention to detail to ensure a secure and long-lasting fit. By following the outlined steps and considering key factors such as deck thickness, fastening requirements, and sealant application, users can achieve optimal results when installing Bomar portlights.
The documentation provides clear and detailed instructions for both portlights and hatches, emphasizing the importance of proper alignment, sealing, and maintenance. These guidelines are essential for ensuring the performance and longevity of the portlights, particularly in challenging marine conditions.