Last FYIs,
I finished rebuilding all 4 ports today using the Catalina Direct kit and Richard's example. Tip #1: To get the right amount of window gasket I would dry fit around the window glass and once I got to the beginning I would cut it 1/8 to 3/16 longer. When I completed the final assembly the gasket fit was perfect. Doing the first window was a complete mess and took forever, way too much caulk. Some of my frame sets had bleed holes for the excess caulking to exit and some didn't. The first one didn't... which made it the most difficult. By the time I got to the fourth one, I had adjust the caulking to the right amount, and there was very little mess. When I finished the fourth one it looked like I had been doing this procedure for years. Tip #2: I had the frames on two pipe clamps with 2 x 4s at each end to slowly draw the frame together. Sometimes the ends of the frames would not line up when drawn together, so I would use a third pipe clamp and cross clamp on top of the frames so I could move the clamps together. For example if the top frame was too far to the left to meet the bottom of the frame. One end of the cross clamp would go on the left outside of the top frame and the other end of the cross clamp would go on the right outside of the bottom frame. Turning the clamp would draw the two frames together, worked like a champ. Tip #3: 1 Qt of mineral spirits and 3 rolls of paper towels was the right amount for all four ports.
I do have to say, the Catalina Direct gaskets and caulking (Dow 795) makes a real nice finished fixed port. If I didn't do all the work, I'd swear they were new.