About NFM ports
Why pick them:
1) They are not plastic.
2) There was lots of info about installing them. especially good information here:
http://www.pbase.com/mainecruising/nfm_port_lights&page=1
3) NFM had the package for a Morgan 38 (all the right sizes) so lazy me escaped all that research that would otherwise been necessary.
4) Stainless looks good on a Morgan 38
NFM customer service:
1) I got lots of help when discussing/placing the order. Several telephone conversations, all very helpful.
2) Got a good response when I sent them email asking about the quarter birth port issue. They recommend shimming the outside with starboard (hadn't considered that)
3) Shipment arrived in a timely manner. Got lucky on the router template, they had one on hand. Ordered everything they suggested: butyl, router template, bolts, drill counter sink'..) saves all that running around to the hardware store, home depot, etc.
Installation:
1) I used the butyl caulk. I also slopped lots of polysulfide on the trim ring before bolting it down. Don't ever want to have to fix a leak on one of these things. I like the butyl for filling large gaps. I think it will be good long term.
2) No on 5200. The NFM people do not recommend it. Makes sense. The fiberglass cabin sides expand and contract with temperature and hull flexing at different rates than the metal ports. The needs to be movement between the two parts. The cabin side will crack if the fiberglass and metal port are locked together with 5200.
3) Buy a new router and carbide cutting bits. Plan to wear them out on this job. The cabin sides are ' inch thick glass.
4) Tried to hire a professional for the work. He took one look at the job and never called back. I can see why. Lots of unknowns when taking things apart. He would not have been able to charge me what the work was worth.
5) Installing the first one, in the head, took two full weekends. With practice, I got it down to one day per port. A professional could probably do it in half a day. I spend a good deal of time staring at the hole wondering if I'm doing it right.
The ports look terrific. They don't leak.
Now if I can just finish off this last one'.