Airline_BoatUSAd_10-12.qxd:Layout 1 10/18/12 4:14 PM Page 1
Next, drill the holes for the mounting
hardware following the recommendations in
the instructions for the port. Be aware that if
you are using screws rather than thru-bolts or
well-nuts to hold your port in place, you will
need to drill pilot holes that are slightly larger
than you would for screwing into wood. You
want the threads of the screws to just engage
the edges of the hole in the fiberglass.
Once you’ve made the holes, go back
with either a countersink or an oversize bit
and chamfer the holes just enough to remove
the gelcoat. If you’re afraid of drilling too
Dry-fit the port before using any
sealant. The port should fit easily
with about 1/8-inch clearance all
around (top). Use sealant liberally and
then tighten the port into place until
the sealant just starts to ooze from
the edges. Don’t tighten it all the way!
We used black sealant for this
demonstration. White or clear are
the usual choices.
onto the boat. Insert the blade of your jigsaw,
reciprocating saw, or similar tool, and begin
cutting along the traced lines, running the
tool at full speed to reduce splintering and
chipping of the gelcoat. Which tool is best
for the job? The one that gives you the greatest control while fitting in the space where
you are making the cut.