First off, don't be fooled by these pics. Those port are four different shapes and sizes. You'd think they would have had a jig of some sort at Pearson. Hell, at least a pattern to trace!
We've concocted a little jig for the job. In theory, it should provide the female form for the epoxy blend that will become our port, provide the pattern for the lexan for the lite, and act as the placement jig for the holes to be drilled and tapped for the stainless bolts and, yes, be a cutting and drilling jig for the inside frames. And as an added bonus, it's made mostly from discarded material.
Ater the some grinding and sanding and surface prep the jig will be clamped to the cabin side through the six holes. Then fill the gap between the existing ports and the jig with the extra special epoxy blend. Then wait. Once she has an intial cure we can 'pop' off the jigs and take a look. Then the jigs go back on and we drill all of the holes. Once the hole are drilled then off comes the jig and in goes the tap. When the hole are tapped we'll drill a countersink for the bolt heads. Once the bolts are screwed in...well, it's all down hill from thereA little fillin' and fairin' and we're ready for primer.
Here's a picture of the jig...
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