I ripped out the leaking and crumbling 20 yr. old Gray ports and let everything air dry for about 3 weeks

Taking the plunge

Once the core was good and dry, I took a router with a 3/4 dado bit and cut back the core about 1/8, leaving the fiberglass skins on either side to form a lip for the epoxy putty to fill flush with. Note the inner headliner will also be bonded.

Routed the core

Lots of West epoxy thickened with microfibers. The C-clamps are holding the headliner tight against the cabin structure, while the epoxy sets.

The messy part

With the epoxy set and clamps removed, it looks rough, but at least water cant get in the core anymore. Note the old drain channels for the Grays are filled in and the new channels for the Raindrains are cut outside.

Still pretty rough

The 5 x 12 ports fit right in the old holes, but the Beckson 7 x 14 port is not as wide as the Gray, so some mahogany Dutchmen - little pieces of wood - have been glassed in to make the hole narrower.

Dutchmen

Here is a 7 x 14 Beckson Raindrain, with the dutchmen showing. The trim ring will cover them.

Final fitting

Lots of silicone used to bed the ports in. Clean up with an exacto knife and a razor blade scaper once dry. Sit back, have a beer and admire ones work...Ah!

All done