Wow - you only had #4's? Tiny indeed! Mine were (are) held together with #10's, at least. 9 of those, per deadlight. I wonder if they used smaller fittings on earlier boats, mine being near the end of the production run...?
What I noticed WRT the 'space between' on Katie is that it is easily closed at the bottom and most of the sides of the deadlight hole. At the top it's a different story, due to the curvature into the overhead. Top forward corner of the strbd forward deadlight, it cannot be brought together, the liner hole is cut wider than the doghouse hole. Likely stuff some epoxputty into there, everywhere else just gets bonded together with a bit of thickened epoxy and clamps.
What the Smeeton's and Guzwell pulled off down there in the deep SoPac, *that* is the embodiment of true seamanship to me. IIRC, Beryl was even swept overboard when that happened. Scary stuff! Good reading, though.
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Also, today I did a bit more interior aft bulkhead carving and have now extended the berth aft to the new forward footwell edge. Where I currently have the forward berth edge gives me a berth approx 80"x44", a "small double". Plenty of room to add in 10" more on the front for a "full double" size, but being solo at this time, I am opting for more footroom on the cabin sole. Plenty spacious for me and CrewDog Barque.
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