aft hatch - Starboard side

[MM33]

Its Square and smooth. No, no skid on it anywhere. I dont think there is a core either. The width of the hatch throughout is about 1/4 inch or so.

[billythekid]

the hardest thing about making that hatch is matching the color. do you know if the boat is original gelcoat or has it been painted?

[MM33]

original gelcoat

[MM33]

what kind of saw did you use cut the mold?

[billythekid]

for the MDF I used a jig saw with a small bladed with a medium tooth, the MDF cuts really easy and with the small blade tight radiuses arent a problem.

[MM33]

Just a question why I would nail the template on top of one another? Is MDF thin so you need 2 nailed together to form a template?
Also, Do I put anything down when I do the Gelcoat layer, or is it just Gelcoat mixed with MEKP. I got a little confused with the sentence "then 2 layers of mat for what is called the skin coat" what do I lay down the 2 layers
of mat with??

Step 1 - I would put the hatch you have down on a piece of MDF and scribe twice on two peices. cut the inner section out of both of them so you have 2 outer templates. screw, nail or staple them together one on top of the other.

Step 2 - get some sculpy putty and raduis the hard edge on the bottom like the other hatch.

Step 3 - wax the mold

Step 4 - get a pint of gelcoat from any marine store. roll the gelcoat down mixed with MEKP. then 2 layers of mat for what is called the skin coat, it is important that you get all the air out of these coats.

Step 5 - Once that kicks, 2 layers of 1708 biaxial. Depending on whether or not the hatch is cored, then you would core it with some 3/4 ply would in the middle.

Step 6 - Then a couple more layers of 1708 and you are done.

[reelclassic]

After 3 or 4 coats of wax (PVA) Brush or spray on the gelcoat let it cure and then start building it up with the matt

[billythekid]

you have it. A couple things I would add. Lay the gelcoat up thick, you are going to have to sand around the edges. let the gelcoat sit for about 45 minutes. If you start laying up resin to soon the MEKP from the resin will attack the gelcoat and will aligate (looks like aligators) get yourself a fiberglass laminating roller. 3"x 1/2" should do it. go for it!

[reelclassic]

I did have some alligator on one of my hatches I did and went ahead and finished the cover and then used some evercoat 400 to repair the bad spot after it came out. So if you do get it keep going and fix it after it comes out of the mold. But mine are getting painted so you cant see the repair!

[MM33]

Any specific brands you guys like for PVA and gel coat?? thanks again for this info.