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I wonder if one of those headlight restoration kits you see at Autozone would work on the plexiglass?  Might be an inexpensive way to get you through another season.

I'd fill with some butyl gasket.

With gas up as much as 80% over last summer I'm glad we all have sailboats.  I figure if I use my typical 1/2-3/4 of a tank I'll only be paying an extra $22.50 for a summer of enjoyment on the water.  Will be interesting to see how many powerboats are sitting at the docks this summer.

When I do the first spring cleaning I'll spray with Ka-Boom (can get at supermarket).  Let it sit for a min or two then use a bucket of boat soap/water and a scrub brush.  Takes most if not all of it off.

I also filled mine with Dow 795 but any black sealant should work. 

Taped off around the groove.  Filled with the sealant then ran a razor blade (or anything with a flat edge) along the groove to flatten out the top of sealant.  Wait until it dries and peel off the tape.  Mines been going strong for 9 years.  I don't find it helps with grip at all but keeps the grooves clean.

I do have my "magic socket".  It's just a cut down socket.  Let me know if you need it and i'll ship it out.

I'll be down pulling everything out this weekend.  Cover will probably go on next weekend.

I have a similar cover but mine is above the rub rail.  I tie down the bow and stern.  Hang 4 gallon jugs off each side. 

Tie off the bow to the anchor cleat.
Hang 1 gallon off each side halfway between the bow and 1st standing rigging.
2nd gallon somewhere between the standing rigging.
I'll also take a bungy cord and go through 1-2 grommets mid ships and tie them off to the lifeline stanchions
When I get to the cockpit I hang 2 gallon jugs each side at the start and end of the cockpit
Stern gets tied off on the stern pulpit.

I'm in New England.  Been doing this for the last 9 years.  Never had an issue.  Been on the boat in February, working, during  strong blow and the cover barely lifts.  The gallon jugs really hold it down.

I'll go with Crazy.

I'd try the sanding.  Worked instantly for me. 

Give
DMImarine.com a call.  774-213-9744.  They refurbish the original Datamarine units and should be able to point you in the right direction. 

Yes, I'm sure it will.  Great wealth of knowledge on this forum.   It was a small amount of sanding I did with very fine sandpaper.  Amazing how the pump went from no flow to full flow with just that little amount of sanding.

I had the same issue with my lab.  She was 6 by the time we got our first boat.  Just couldn't get comfortable on it, and we never even sailed with her.  Just the rocking, of the boat, at the dock was too much for her.  Couple people at my marina have dogs.  Ones a Yorkie.  Others look to be mutts.   I think the key is getting them on the boat when they are puppies.

Went down this morning and tried Stu's technique with the sandpaper.  It worked! Put everything back together, turned the engine on and water started coming out of the exhaust.  Let it run for a while, temp got up to 160* and held.   Thanks for all the help everyone, appreciate it.

Took the strainer apart and checked it out. Then reconnected the strainer to the seacock  hose and opened the seasick. Water came out the barbed fitting where the hose to the water pump connects.

Strainer to water hose. Disconnected and blew through it with my mouth. Water sprayed out the other end.

So even a slight gap between the faceplate and impeller will cause the water to not flow?  I would think the impeller would have enough oomph to overcome that.

When I run the engine for a few minutes, then pull the faceplate off, the pump housing and hoses are dry like it hasn't pulled any water at all through. I would think if the faceplate gap was the issue it would pull something just maybe not enough.