Replace Forward Hatch

Both hatches were in a pretty grotty state with crazed glass, corroded frames, sheared bolts and broken fittings. They could have been restored at some expense but still the light coming in would not be what it could be. We went for replacement. The usual financial investigation indicated an import - this time from New Zealand.

Once the old hatch had been removed, the deck could be measured up for cutting (the new hatch being about 5mm all round bigger than the old). The excess was dremeled away and the gap filled with epoxy fairing mix. The old screw holes were drilled out and filled with epoxy to seal them, and new holes were drilled oversize and filled ready for the new self-tappers.

The hole fully prepped.
Before embedding the frame in Sikaflex, the deck and frame were masked off. The plan is to run seal around the mating area, and snug the frame down with self-tappers. Then the masking tape can be removed and the Sikaflex smoothed down with a finger.

Deck and frame masked prior to embedding in Sikaflex.
Next day the frame can be screwed down tight and the hatch fitted to its frame.

Fitted hatch.
 

Hatch dogged down.
The last thing that needs doing here - and its a job that can wait for a while - is to rub down the epoxy for any old holes that lay outside the hatch rim. These will be exposed to the sunlight and I'm concerned that, over time, UV will break them down. Once they have been rubbed down a couple of mm, they can be filled with gelcoat repair and buffed up to a nice deck-like shine.