Hey guys,
Thank you all for posting. Your input is greatly appreciated.
The port holes are roughly 8"(H) X 16"(L) X 1" (T). There are ten windows of this style all together. We are refurbing what we can. Soda blasting to bare metal, repairing with JB weld and painting. At some point all the port lights were removed and stored. They were replaced with one inch thick Lexan. The Lexan is beginning to deteriorate and crack and does not properly seal. Not to mention they look like crap. I removed the Lexan lights and reinstalled the old lights with new gaskets. Unfortunately two are missing. If the price were right I would replace the ones in the worst condition plus the two missing. As for time? The sooner the better but what choice do I have? So however long it takes, it takes.
I am not opposed to 3D printing if the material will hold up to being dogged down. Heck I have even thought about trying to press a mold in some clay and filling it with JB Weld.
I have not spoken to Port Townsend but I will. There is a foundry in NC that I spoke to. I'm waiting on an answer.
LWJ- you can see the boat here.
http://forums.pelicanparts.com/off-topic-discussions/870616-gm-671n-marine-diesel.html