I have subscribed to Practical Sailor for years. Although I have a power boat, I like your philosophy for thinking small. You may use this info as you see fit.
Porthole Screen Project
My porthole screens were starting to deteriorate after 10 years. The old screens were a fiberglass mesh. I looked into replacements, but could not be sure of pothole manufacturer or their exact size. What I did find seemed to be quite expensive at $40 to $50 each.
I decided to use bronze window screen as a replacement. This costs about $3 per square foot, purchased at a hardware store. I used plastic sign material for the screen frame. This costs about $6 for the heavier “No Parking” sign (18” x 24”).
- Initially, I cut a dummy frame, using the outside of the old screen as a pattern. It took a little trimming with scissors, but finally got the dimensions right and popped it into the porthole frame. I had cut a couple of 1-inch diameter holes in the plastic so I could handle the dummy from one side.
- Using the overall dimensions from the dummy, I cut four frames on a table saw. I layed out and cut the inside curved sections of the frame, using a 3-1/2” hole saw. I then cut between the edges of the holes to form the opening. I trimmed the outside corners to match the old.
- I cleaned things up with a Dremmel tool and spray-painted both sides with flat black, which was compatible with plastic.
- I cut the bronze screen with scissors to fit the frame, backing it off about 3/8-inch from edge of the frame.
- I weighed the screen down with cans of olives (soup will also work), and glued the perimeter of the screen to the frame with a good quality Super Glue.
- I made the edges of the new frames wider than the old frames since I eliminated the frame’s “center post.” The new screens popped right in with the glued side of the frame on the inside. To remove a screen, it may be helpful to have someone push the frame from the inside.
The new screens should last for years.
David Bogdanoff
Beauty 27
San Francisco
