aft hatch - Starboard side

[MM33]

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.

[reelclassic]

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

[MM33]

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

[reelclassic]

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.

[MM33]

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?

[Old'sCool]

Won't stick.

[Bushwacker]

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.

[2182]

either use "starboard" (beefy plywood crossed w/ azek) for the synthetic look or use teak and a biscuit joiner and make it from scratch, then cut to size...imin charleston too and have biscuit joiner you can use if you want to go that route...