aft hatch - Starboard side
 

I had my boat delivered to me from Long Island to Charleston, SC. In transit my starboard aft hatch flew off (on I-95, not killing anyone thank god). I have a 1984 23cc and need to figure out how to get a replacement or make a set of custom hatches. Any ideas for getting a replacement or what type of material I should use to replace it (starboard, etc???) Thanks for any info.

Re: aft hatch - Starboard side
 

I was going to use sarboard to build the 2 hatches in the rear....But i decided to make a mold and build them from scratch...I am no professional by any strech of the imagination and they turned out "almost perfect" much easier than I thought is was going to be. I strongly recommend doing that I had a starboard hatch and they really dont look good. I ended up fabricating all of the hatches(2 in the back and the ancor locker and fish box) and very happy with the results! I made the mold out of an old formica cabinet door that i had laying around work perfect! You will also come out cheaper as the 3/4 inch starboard you will have to buy aint cheap! good luck

Re: aft hatch - Starboard side
 

Not too sure how I would go about making a mold. I never have done any glass work.

Re: aft hatch - Starboard side
 

I had never done it before either....you would lay up formica or I think you can do it directly on MDF someone else may be able to chime in on that, anyways all you do is make a box screw or nail strips however big the edges need to be and get some modeling clay and place in the corners to form your radius edges and then spray about 3 or 4 coas of pva mold release then spray or roll on gelcoat then 2 layers of mat 1 1/2oz. your core material a layer of roving 2 more layers of mat trim the excess and pop it out! It was the first time for me and mine turned out really nice ill try to ut up some pics.

Re: aft hatch - Starboard side
 

Pics would be great, thanks. I was thinking about using starboard (Sea Foam color) and if it didnt match that well then I could gel coat it to match (I think you can gel coat Starboard). What do you think of that idea?

Re: aft hatch - Starboard side
 

Won't stick.

Re: aft hatch - Starboard side
 

PVC foam board such as Azek is another option, much easier to work with than starboard - can be sanded, routed, screwed, glued with pvc cement and painted. Seems to work about like soft pine; probably is similar strength. Only problem I found is that if you use a saber saw on it, use a very course blade and low speed; even that generates enough heat that the chips tend to melt back together behind the blade! I used it to replace rotted 3/4 plywood on a Seafari galley seat and was pleased with result. A 4x8 sheet is about $100, probably a little cheaper than starboard. Another member/building contractor posted a tip on it here a few months ago. I believe he built some console doors or hatches with it.

Re: aft hatch - Starboard side
 

go to Wal-mart and buy a Cutting Board and cut to size.

Re: aft hatch - Starboard side
 

Yeah, and while there you could get a George Foreman grill to bolt down on the forward casting deck....that'd be stylin' [img]/forum/images/graemlins/tongue.gif[/img] I think Spidercrab may have already gone this route, can't recall....

Re: aft hatch - Starboard side
 

this sounds like a job for Hermco, Do youself a favor and either build one or have one built. to slap a piece of plastic over the hole isnt going to exactly cut it.

Re: aft hatch - Starboard side
 

Can I make a mold of my other hatch? is there anything I can use to make a mold with?

Re: aft hatch - Starboard side
 

yes use the other hatch to make the mold that way they are exactly the same size! you can use MDF or formica!

Re: aft hatch - Starboard side
 

what is MDF? if you use formica, how do you get it to mold to the shape you need? do you cut it?
thanks

Re: aft hatch - Starboard side
 

You should search either hulltruth or classicmako for Ringleader's boat.....plan a few hours of reading/studying pics...he's the master and does all of it! Very educational!

Re: aft hatch - Starboard side
 

MDF=Medium Denisity Fiberboard home depot or lowes has it pretty cheap. Formica you would glue formica to wood(flat straight wood) cut strips off it to screww or nail to make the edges i made my edges 7/8 or so and trimmed off the excess with the table saw after it came out of the mold. I will try to take ictures of the mold tomorrow and post for you!

Re: aft hatch - Starboard side
 

mdf

http://i113.photobucket.com/albums/n...7/DSCN1125.jpg

its smooth easy to work with easier to cut and cheap as spit.

Re: aft hatch - Starboard side
 

I see, whats the white material behind the MDF?
I appreciate everyone's input. I think I may take a stab at it!!

Re: aft hatch - Starboard side
 

The panel behind it is malemine (spelling?) you dont need that though you can use MDF under it. I would put the hatch you have down on a piece of MDF and scribe twice on two peices. cut the inner section out of both of them so you have 2 outer templates. screw, nail or staple them together one on top of the other. get some sculpy putty and raduis the hard edge on the bottom like the other hatch. wax the mold. get a pint of gelcoat from any marine store. roll the gelcoat down mixed with MEKP. then 2 layers of mat for what is called the skin coat, it is important that you get all the air out of these coats. then once that kicks, 2 layers of 1708 biaxial. and depending on wether or not the hacth is cored then you would core it with some 3/4 ply would in the middle. ( I have some marine play in 4"x4" squares that you are welcome to. and a couple mor layers of 1708 and you are done. here are some hatches I just made so you get an idea.

http://www.classicseacraft.com/forum...=&fpart=4&vc=1

half way down the page you will see the molds on the table and the layup.

put some detailed pics of the hatch you still have and maybe some other can chime in on how to make a replica.

Re: aft hatch - Starboard side
 

HERE IS THE HATCH I AM TRYING TO DUPLICATE.

http://img258.imageshack.us/img258/6779/dsc00544zw1.jpg

http://img151.imageshack.us/img151/7091/dsc00542rl0.jpg

Re: aft hatch - Starboard side
 

is the hatch square? or is it tapered? does it have any type of factory non skid on it or is it smooth?

Re: aft hatch - Starboard side
 

Its Square and smooth. No, no skid on it anywhere. I dont think there is a core either. The width of the hatch throughout is about 1/4 inch or so.

Re: aft hatch - Starboard side
 

the hardest thing about making that hatch is matching the color. do you know if the boat is original gelcoat or has it been painted?

Re: aft hatch - Starboard side
 

original gelcoat

Re: aft hatch - Starboard side
 

what kind of saw did you use cut the mold?

Re: aft hatch - Starboard side
 

for the MDF I used a jig saw with a small bladed with a medium tooth, the MDF cuts really easy and with the small blade tight radiuses arent a problem.

Re: aft hatch - Starboard side
 

Just a question why I would nail the template on top of one another? Is MDF thin so you need 2 nailed together to form a template?
Also, Do I put anything down when I do the Gelcoat layer, or is it just Gelcoat mixed with MEKP. I got a little confused with the sentence "then 2 layers of mat for what is called the skin coat" what do I lay down the 2 layers
of mat with??

Step 1 - I would put the hatch you have down on a piece of MDF and scribe twice on two peices. cut the inner section out of both of them so you have 2 outer templates. screw, nail or staple them together one on top of the other.

Step 2 - get some sculpy putty and raduis the hard edge on the bottom like the other hatch.

Step 3 - wax the mold

Step 4 - get a pint of gelcoat from any marine store. roll the gelcoat down mixed with MEKP. then 2 layers of mat for what is called the skin coat, it is important that you get all the air out of these coats.

Step 5 - Once that kicks, 2 layers of 1708 biaxial. Depending on whether or not the hatch is cored, then you would core it with some 3/4 ply would in the middle.

Step 6 - Then a couple more layers of 1708 and you are done.

Re: aft hatch - Starboard side
 

After 3 or 4 coats of wax (PVA) Brush or spray on the gelcoat let it cure and then start building it up with the matt

Re: aft hatch - Starboard side
 

you have it. A couple things I would add. Lay the gelcoat up thick, you are going to have to sand around the edges. let the gelcoat sit for about 45 minutes. If you start laying up resin to soon the MEKP from the resin will attack the gelcoat and will aligate (looks like aligators) get yourself a fiberglass laminating roller. 3"x 1/2" should do it. go for it!

Re: aft hatch - Starboard side
 

I did have some alligator on one of my hatches I did and went ahead and finished the cover and then used some evercoat 400 to repair the bad spot after it came out. So if you do get it keep going and fix it after it comes out of the mold. But mine are getting painted so you cant see the repair!

Re: aft hatch - Starboard side
 

Any specific brands you guys like for PVA and gel coat?? thanks again for this info.

Re: aft hatch - Starboard side
 

I just used what the "guy" at the supply house recommened! The pva was 7.99 and the pint of gelcoat was 20.00!

Re: aft hatch - Starboard side
 

I was wondering what type of mold release to use. The guy at west marine said Mcguires sells a good one. How many coats do you put on? If I use plywood for the mold, isnt it too porous to wax? I am trying to understand the process, any feedback is much appreciated.

Re: aft hatch - Starboard side
 

ok MM33 I am going to take a picture of the mold I used so so you can get see exactly how I did mine. If you look at the pictures of my project "1979 project started" Those are the hatches I made.

Re: aft hatch - Starboard side
 

I am making my form out of MDf that is backed by a smooth piece of maeline. I have one question though, the inside edges of the form will be MDF, which is kind of porous once you cut it. Before I put the mold release down do I have to put something over those porous edges? I am also going to make an edge using sculpting clay, does that get coated with mold release too? Does the clay dry?

Re: aft hatch - Starboard side
 

form your corners with the clay and spray everything with the pva.

Re: aft hatch - Starboard side
 

Do i need to wait for the clay to dry? Also, I shouldnt be worried about the edges that are kind of porous?

thanks

Re: aft hatch - Starboard side
 

no you dont need to wait for the clay to "dry" I dont tink you need to worry about the porous edges

Re: aft hatch - Starboard side
 

what did "billythekid" use for his inside edges for the mold shown above? It looks like Silicon or something like that, he didnt use clay. I am trying to use clay but am having a hard time getting it smooth enough and I dont want a wavy corner edge. Any suggestions on what to use to get it smooth? I will post pics of my mold. thanks

Re: aft hatch - Starboard side
 

A wet spoon

Re: aft hatch - Starboard side
 

Hey, MM33,

Take a look through Strick's famous thread "Here we go agian" and you'll find a pic or 2 of him using the back of a spoon dipped in water to smooth out and "trim" the sculpty clay in the edges of the molds he made. Worked like a charm!!!! :cool: :cool: :cool: :cool: