Manny,
Did you use the Bomar 2092 to replace your forward hatch? Does anyone know if there is an aluminum frame comparable to the 2092? I have replaced the lexan and chased a variety of leaks in regards to this hatch but know that in the end I will need to replace it. I currently utuilize hatch covers that are held in place with bungee's.
Jimboyyy,
I didn't use the Bomar to replace. I decided to make new hatches. I used Ipe for the exterior frames and oak for the flange and and interior of the top of hatch. The exterior of the top was about four or five layers of cloth.
I started by making cardboard templates of the interior openings. I then used that to make the oak flanges. I then used the flanges to size the Ipe frames. I cut lap joints for the corners of the frames and epoxied them together. I then epoxied the lower frames to the flanges and glassed them in from underneath. The upper frames once epoxied together I laid up the layers of glass and then placed the frames on top of that, then dropped the oak insert and used weights on everything until it dried. I ended covering all the wood with two coats of epoxy and then about six coats of varnish. The fiberglass tops I painted with Brightside. I used sea dog hatch adjusters and the latches were from defender. I backed everything with brass plates.
It turns out that when I went to install the hatches I didn't take into account the taper of the cabin liner around the hatch openings. I had to grind some of the liner away for the hatches to fit but it was minimal. I also discovered at the front hatch there were voids between the interior liner and the exterior, which was the cause of the mystery leaks in my v-berth. I filled them with 6-10. I tried to use butyl tape to seal the hatches but cabin had a bit of sag in the center so it was too much of a gap on both hatches. I had to pull them and re-bed them with lifecaulk. No more leaks from either hatches!!!! :dance:
I don't think I spent more than $200 on the whole project since I had most of the materials. I didn't have the money for new hatches so I figured I give it a shot plus I kind of like the look of wooden hatches. I found that they are much more substantial than what I removed. I even found myself putting all my weight on the front hatch when I was bedding it. If I even pushed on the original plastic it would flex like crazy. They are not perfect but they don't need to be. I'll be happy if they last 5 years!
M