Making the hole smaller

[idonthaveaname]

I am replacing the deck hatches on my Proline and having a hard time finding the exact size. The hatches are slightly smaller but so the hole is too large. I would like to fill in the space but would like some opinions. The deck is about 1/4 thick and I would need to fill about a 1" width on a 13" (side) space. Granted I could form and fill with filler but it would it hold? Any thoughts?

 

[Woodonglass]

Re: Making the hole smaller

Here's how I'd do it. If you can get to the under side of the side of the hatch you would install a piece of 1/2 plywood as a cleat by screwing it from the topside and countersinking the screwheads and patching with pb. You would then Mix up some Hairy Peanut
Butter with lots of cut up CSM strands to give it a lot of structural strength and fill the 1" wide gap needed and make it a bit high. then Sand and smooth to final thickness. I think this would hold up well. You might want to grind it down a bit an lay layer of csm over the seam to keep it from developing a crack there on the seam. That's my 2?

 

[GT1000000]

Re: Making the hole smaller

Wood's suggestion is a preferred way, IMHO...you could also add a layer of CSM to the cleat before installing it with the screws, if you can grind the underside a bit to get a good bond...another alternative would be to use 5200 to glue the cleat to the underside for added strength...
The only thing I would maybe change is instead of filling in the void with thick PB, is to make a filler piece of plywood to take up most of the space and then 5200/CSM it all together...
Another possibility is to get some extruded aluminum in a Z shape...attach to the opening on top of the deck with SS screws and 5200...
I don't think it would be as strong as the repair involving fiberglass, though...unless you add the cleat also?

 

[pauloman]

Re: Making the hole smaller

I would make a wood frame that fits into the old hole and reduces the inside opening by the right amount. the attach the new hatch to the new wooden 'picture frame' you created.

 

[Woodonglass]

Re: Making the hole smaller

Pauloman, It's 1/4" thick and you say Nothing about how you would attach this Picture frame to the existing deck. Details would be helpful.

 

[idonthaveaname]

Re: Making the hole smaller

Thanks Wood - That's close to what I was thinking would work. I "get" the picture frame idea, but that would create more of a step than I want. Hey Gus.... Your mention of the extruded aluminum got me thinking about the deck replacement on my other (bass) boat and solved a problem for me.

Awesome work guys! Thanks.

 

[idonthaveaname]

Re: Making the hole smaller

One last question (maybe). Once I reduce the size of the hole, there will be a "border" showing the repair. I want to paint it in order to match everything else, or I suppose I could gel coat the area (?). It's an area that would receive a lot of foot traffic.

What paint should I use? TotalBoat Wet Edge Topside Paint? Interlux Interdeck Polyurethane Non-Skid? Or would a good enamel do the trick? Any recommendations?

 

[Woodonglass]

Re: Making the hole smaller

If, once you fill in the extension with the Hairy PB, you grind down and back the existing lip about an inch or so and also some of the PB so you get a dished out effect and then refill this with strips of CSM and resin and then sand, fill with 3M premium filler and do you final fairing. You should not have much of a noticable "Border". It should blend fairly well. ( I hope all that made sense??)

If she's gunna get heavy use, then I'd use a Preval Spray and spray some gelcoat. Since it's white you could play around with a kit and prolly kit pretty close to matching it color wise.

 

[fishrdan]

Re: Making the hole smaller

I am replacing the deck hatches on my Proline and having a hard time finding the exact size.

It would probably be easier to build the proper sized hatch covers from scratch, opposed to building out the opening in the boat. A piece of 1/2" 5-ply plywood, epoxy sealed with a layer or 2 of fiberglass cloth would be very strong.

How deep is the lip from the deck surface? (Would 1/2" plywood make the opening level to the deck?)

 

[jigngrub]

Re: Making the hole smaller

I dunno, but the fixes I see in this thread look kinda weak to me... especially for a high foot traffic area.

Can you make the hole bigger and install a bigger hatch?

Or if you go smaller maybe fir out your bulkheads below to support the cantilevered scabs or angles?

... or as FD suggests fabricate your own custom cover to size.

 

[idonthaveaname]

Re: Making the hole smaller

The top and bottom fit perfectly. It's only the sides that are lacking a small area. Even with that, the lip of the hatch extends beyond the left and right so the only exposed area after the repair will be the corners. I believe 1/2" 5-ply plywood, epoxy sealed with a layer or 2 of fiberglass cloth will be strong enough especially when adding a 1/4 inch of reinforced Hairy Peanut Butter. Finding a hatch to fit is a tough challenge--it was originally a teak wood formed hatch. I have looked all over and considered going larger (that would be ideal) but there is nothing available. Granted, I can have one custom built but daaaaaayum that's expensive.

 

[idonthaveaname]

Re: Making the hole smaller

Assuming what you see here is square (it's not because of the camera angle).

The blue line is the outer edge of the hatch and the red line is the piece that fits in the hole. As you can see, the top and bottom are fine but the side don't quite make it.



Make sense?

 

[Woodonglass]

Re: Making the hole smaller

What's the total thicknes needed for the hatch cover? what are the exact measurements needed for the hatch opening as it exists right now. And if you would, be precise in the measurements. I do have my reasons!!!!

 

[idonthaveaname]

Re: Making the hole smaller

The deck hatch opening (first pix) is exactly 22 1/2 X 12 1/2. The deck where the hatch would seat (third pix) is 1/4 inch of solid glass.

I am not quite clear as to what "What's the total thicknes needed for the hatch cover" means. Maybe I am too thick?

 

[idonthaveaname]

Re: Making the hole smaller

YAY!! All I need to do is the finish work. I pushed the hatch to one side and fabricated the space as Wood suggested. Now on to some sanding and paint/gel coat. I also found a great buy to fill the hole above this one. As you can see it's a locking hatch with storage drawers. I found this one for $40 in perfect condition. Sweet!!

Thanks for all the suggestions!!

 

[Woodonglass]

Re: Making the hole smaller

Happy it worked out for you! Make sure and post up some final pics!!!!

 

[idonthaveaname]

Re: Making the hole smaller

Final pic gentlemen. Thanks for the input. I believe that I will paint the hatches to match the finish but other than that I am very happy with the outcome.

 

[GT1000000]

Re: Making the hole smaller

Nice job!
They look like they have always been there...

 

[Woodonglass]

Re: Making the hole smaller

I can't believe you would post pics of such a terrible job! All the other guys that come along and see this will wonder why you ever attempted this job! Such shoddy workmanship and such a terrible outcome. Why did you ever think you could DIY those hatches and come out with a professional looking job????


Oh wait, I had the Admiral's glasses on!!!


WOW... I take it all back!!! Those turned out GREAT!!!!!! Now look what you started...EVERYONE will think I CAN DO IT!!!!!!


You get one of these...

 

[idonthaveaname]

Re: Making the hole smaller

Thank you gentlemen. You have made all that effort very worthwhile.