Ok, so here's the hatch that came with the boat, it was fogged up and sagging in the middle. It appears to be lexan. The dimensions are 35.5" x 30". I measured the thickness at 5/16".
I ordered a new piece from
TAP Plastics in 1/2" Acrylic. The color is Lt Smoke. I had them radius the corners 1/2" and round the edges. I was disappointed to find that they only rounded the edge on 1 side. If I did it over again I would ask they round both sides. The cost was $290 shipped to my door in less than a week. It fits perfect in the opening.
HOWEVER, it does NOT fit under the fiberglass cover--it is too thick, causing the teak rain deflector to rub on the fiberglass. I will be trimming the teak and then I am confident it will fit. Will report back on this later.
Based on a compilation of (sometimes conflicting) advice from multiple threads on this forum, I cut a 'rain groove' in three sides on the bottom, 1/8" deep and 1/4" wide, 1/2" from the edge.
I also cut a rain groove in the top rear, about 1.5" from the rear edge.
As you could probably deduce I was unable to finish this last weekend so I will modify the teak and hopefully have finished pics next week.
-Z