![Image](http://i962.photobucket.com/albums/ae106/Hirilonde/DSCF1128.jpg)
The ports themselves are simply 1/2" poly carbonate cut to shape and to overlap the rough openings in the cabin sides. Then the entire perimieter of the pieces are rounded over on a router and polished to near clear. The pieces are then through bolted to the cabin over a generous bedding of Sikaflex 291-LOT The bolts are counter sunk oval heads on the exterior and just long enough to accept a washer and nut on the interior.
The interior trims are all made from a single pattern. They overlap the interior of the cabin sides by a wide enough margin to cover all the nuts/bolt ends. They also over lap the polycarbonate. The are made totally in the shop out of 4 pieces cut on the bands saw. They are mitered and splined at the 4 corners to make a unit. They are then faired, smoothed, and routed over on the inside and outside edges. I then rabbeted the back sides to sit flush on both the polycarbontate and the fiberglass interior of the cabin. I then layed out the locations of all the nuts/bolt and using a forstner bit I drilled a recess to encase the nuts/bolts so as not to hold the trims away from the cabin and ports. I then finish sanded, varnished, sanded, varnished, yada yada until pleased. The trims were then installed as opposite pairs simply by bedding them in place with Sikaflex and using sticks across the cabin to hold the opposite pairs in place while the Sikaflex cured.
The 4 trims are identical in shape so 2 pairs of mirrored trims. The rabbet and nut/bolt recesses were done individually, so now each trim fits only a specific port. It was a somewhat tedious project to get all 4 to fit their assigned port. But it meant if aligned properly during installation, each port would look identical and be aligned on the interior. The original openings are not beautifully cut out, but I did not want to enlarge anything.
I hope this answers the questions.