OH DEAR!

Aug 11, 2011
857
O'day 30 313 Georgetown MD
I have started the restoration of the companion way hatch. The hatch is not in a great condition, in fact worse than expected.
First I put two coats of epoxy on the topside to help keep the form of the hatch.
Hatch 8.jpeg

Then I turned it over and cut out the raised area which holds the Balsa boards
The piece that I removed had balsa attached to it also. Apart from one small corner, everything was water logged.
Hatch 3.jpeg

I cleaned it all out carefully
Hatch 5.jpeg
Once it was all cleared out,
Hatch 4.jpeg

I ground down the edges, washed with Acetone, ready to put a coat of epoxy on the inside
IMG_2958.JPG

More to come.......
 
Oct 19, 2017
7,732
O'Day 19 Littleton, NH
Wow, nice work on a difficult piece.
:clap:

Just thinking, if that's what the hatch looks like, how does the cabin top around it look? Does it feel like the core is solid pr is it squishy?

-Will (Dragonfly)
 
Aug 11, 2011
857
O'day 30 313 Georgetown MD
Update:
All the above was done on day one. Day two, I put down a coat of epoxy resin to seal the cleaned up interior surface. Today, day three, I laid a single layer of fiberglass strand cloth down, with slow curing epoxy resin.
The plan is now to get some 3/8th pvc board, 32x32, cut grooves one way to let it curve to the shape of the interior, epoxy that in and fill the gaps with thickened epoxy resin. Once cured, seal it all in with a woven fiberglass cloth mat, and a final coat of tinted epoxy resin.
Picture of today's work
IMG_2960.JPG
 
Jun 14, 2010
2,081
Robertson & Caine 2017 Leopard 40 CT
Congrats on what you've accomplished so far. Very impressed. Keep in mind mat is not as strong as roving. Not sure what you meant by PVC board. I would have some concern with the lack of rigidity from PVC unless it is "structural foam" made for the job such as Airex or Divinycell.
 
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Likes: BigEasy
Aug 11, 2011
857
O'day 30 313 Georgetown MD
PVC Board is used in exterior construction for Soffits, gables and facias. Comes in Lumber sizes. AZEEK is a brand name of similar product. Its strong but light in weight. I have used it on the restoration of the boat in many areas mainly because it wont rot like wood.
I made storage covers for the various areas in the boat, mainly under seats and cushions, shelving in the lazarette and 1/4 berth, backing discs for thru hulls, supportive box for the black water tank in the V berth, Battery box shelf, and some other items.

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58127833832__B1D77406-F1D5-4FE0-B926-A83D32FE7794.jpeg

57488992067__C0F94033-D9A1-4AAC-AFEF-F599F9B8432A.jpeg

IMG_2536.jpeg
 
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Likes: Will Gilmore
Jun 14, 2010
2,081
Robertson & Caine 2017 Leopard 40 CT
PVC Board is used in exterior construction for Soffits, gables and facias. Comes in Lumber sizes. AZEEK is a brand name of similar product. Its strong but light in weight. I have used it on the restoration of the boat in many areas mainly because it wont rot like wood.
I made storage covers for the various areas in the boat, mainly under seats and cushions, shelving in the lazarette and 1/4 berth, backing discs for thru hulls, supportive box for the black water tank in the V berth, Battery box shelf, and some other items.

View attachment 169947

View attachment 169948

View attachment 169949

View attachment 169951
That kind of board is not ideal for this application. Not rigid enough and won’t adhere well. Heavy for the strength. I mentioned some better choices my prior post.
 
Apr 22, 2011
865
Hunter 27 Pecan Grove, Oriental, NC
I agree with Captain Larry that pvc board would be a bad choice. The way I understand it, the way a coring works is much like a I-beam works. It is critical that the material that bridges the two surfaces is bonded tenaciously to both surfaces to achieve the I-beam advantage. I don't think pvc board can be adhered well enough to do the job.
 
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Likes: Will Gilmore
Aug 11, 2011
857
O'day 30 313 Georgetown MD
I pieced together three pvc boards, cut grooves in, contact cemented the boards to the inside of the hatch to get the curve in, then weighted the boards down to the inside skin.
IMG_2961.JPG

IMG_2962.JPG

IMG_2963.JPG
 
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Likes: Will Gilmore
Oct 19, 2017
7,732
O'Day 19 Littleton, NH
Fantastic. You have every reason to feel pride in your work.
Thanks for showing it to us.

-Will (Dragonfly)
 
Jan 27, 2008
3,045
ODay 35 Beaufort, NC
Nice job. What's the other side look like? Anybody ever add Teflon strips to the teak sliders to both shim it up to take up for the wear over the years and also to reduce friction making opening and closing the sliding hatch easier? Might be easier to add to the sliding companionway cover instead?
 
Aug 11, 2011
857
O'day 30 313 Georgetown MD
What's the other side look like?
24 0z roving with plenty of slow hardened epoxy. Next is sanding and then a coat or two of cream color or white Interlux Brightside paint. The stain is a mishap with some old resin.


59183158642__0D427B0E-1E0B-4B62-A7F5-7A7714C5CB37.JPG
 
Aug 11, 2011
857
O'day 30 313 Georgetown MD
I put Teflon tape on the hatch cover runners of my previous boat, a Hunter 25.5. Worked great. Will be doing the same on this.