Thalassa has 13 openings for ports: six each on the port and starboard sides and one forward. There are nine openings for fixed ports, and four slightly larger openings for opening ports. The opening ports will be refurbished and reinstalled in their original openings.

One of the four opening ports. Photo taken in 2007.

One of the four opening ports. Photo taken in 2007.

The following photo shows part of the original interior trim for one of the nine fixed ports. The trim consisted of four pieces of shaped teak (you can see one and parts of two). These were attached with screws that are concealed by bungs. The interior trim had a lip that pushed the window into the exterior trim, creating a tight fit that should not leak if properly bedded with silicone sealant. Eventually, however, these seals fail and windows need to be re-bedded. The original trim on the outside looked the same, but with no lip.

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The original interior trim.

The following photo shows the new exterior teak and one port opening. Note that there is no exterior frame. Here the opening is shaped and overlaps the glass house so that a window may be fitted against the teak from the inside.

Fixed port with no exterior frame.

Fixed port with no exterior frame.

Frames are required on the inside, so a prototype was constructed. To create a one-piece frame, four pieces were connected with lap joints sealed with thickened epoxy, creating what is shown in the photo below.

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The band saw makes the outside radii, while the router naturally makes a smaller inside radius.

The piece was finished by using the band saw to cut the outside radii, and using a router to shape the inside, then using the router again to give the outside a nice, rounded edge. The photo shows one of these frames on the outside. The question now is whether to use frames on the outside and inside, or just the inside.

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Frames on the outside?