I am thinking about the hatch to the cuddy...it's like a 28x48" sliding 2 panel unit with a piano hinge going left to right. I am thinking of making a three panel hinged setup so I don't have to remove it entirely when I walk to the bow for mooring. I will make panels apprx 28x20" and rout out the middle leaving a monolithique 3" border and inlaying a piece of tinted lexan or acrylic.
The first thing though is to cover the flat areas at both the passenger dash and helm to recieve new gauge cluster/switches and glove box door/frame. I have used composite boards alot for house trim and you're right...thread strentgh is an issue, especially where this isn't as dense as say Koma or Azek board. I think in some cases like piano hinge where the screws are going into the edges vs. flat...to use longer course threaded ss screws, predrill and heat. On other ares of question...most mfgs make a pvc cement or similar which actually welds the joints together.
I spend most of my spare time on rc planes, building and flying...but now I really want to start in on this. the boat is currently 50 miles away outside and covered. I am looking into renting an indoor space close by to start.
The only thing I am not sure of is how much teak I should replace...I do like some of the accents
Joe