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I scrubbed the boat from top to bottom making sure to get plenty of water on the hatch and there wasn't a single drop of water on the V-birth. I will not be caulking the hatch form the inside - if it leaks I want to know about ASAP even if the balsa core is now completely isolated from the hatch opening and holes for the fasteners).
better than new!

I scrubbed the boat from top to bottom making sure to get plenty of water on the hatch and there wasn't a single drop of water on the V-birth. I will not be caulking the hatch form the inside - if it leaks I want to know about ASAP even if the balsa core is now completely isolated from the hatch opening and holes for the fasteners). better than new!

sebastien
Sep 27, 2021

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I put the hatch back together.

I put the hatch back together.

sebastien
Sep 27, 2021

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I carefully cut out all the excess butyl and saved it because I can use it at a later time.

I carefully cut out all the excess butyl and saved it because I can use it at a later time.

sebastien
Sep 27, 2021

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I got this far and walked away until the next day - then I gave each nut the same
extra half turn to snug it up a little more.

I got this far and walked away until the next day - then I gave each nut the same extra half turn to snug it up a little more.

sebastien
Sep 27, 2021

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Once the butyl tape started to compress I was diligent about tightening the nuts equally as I went around so as not to tork the frame or get unequal compression.

Once the butyl tape started to compress I was diligent about tightening the nuts equally as I went around so as not to tork the frame or get unequal compression.

sebastien
Sep 27, 2021

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On the left is one of the two machine screws that hold the hinges

On the left is one of the two machine screws that hold the hinges

sebastien
Sep 27, 2021

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I also added a little washer of butyl tape to each one and didn't turn the screw head once it made contact.

I also added a little washer of butyl tape to each one and didn't turn the screw head once it made contact.

sebastien
Sep 27, 2021

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The hatch was previously fastened with wood screws (they only threaded the top layer of solid fiberglass and dug into the balsa core. I replaced them all with machine screws washers and nyloc nuts.

The hatch was previously fastened with wood screws (they only threaded the top layer of solid fiberglass and dug into the balsa core. I replaced them all with machine screws washers and nyloc nuts.

sebastien
Sep 27, 2021

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It goes around the corners just fine.

It goes around the corners just fine.

sebastien
Sep 27, 2021

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I used butyl tape (two layers in this application) from Sailrite to bed the frame.

I used butyl tape (two layers in this application) from Sailrite to bed the frame.

sebastien
Sep 27, 2021

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It turned out great and all the screw holes are isolated from the balsa (something the factory should really have done too!)

It turned out great and all the screw holes are isolated from the balsa (something the factory should really have done too!)

sebastien
Sep 27, 2021

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I was pretty diligent when working with the epoxy so I just had to hand sand the edge.

I was pretty diligent when working with the epoxy so I just had to hand sand the edge.

sebastien
Sep 27, 2021

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Thanks to another boater with a rental car I got the third tube I needed to finish the fill

Thanks to another boater with a rental car I got the third tube I needed to finish the fill

sebastien
Sep 27, 2021

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This is what I've used on all the bedding and preventative balsa protection I've done on the boat and I really like working with it.

This is what I've used on all the bedding and preventative balsa protection I've done on the boat and I really like working with it.

sebastien
Sep 27, 2021

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I filled the gap with epoxy in two stages (partly because my epoxy order was short one tube and getting some locally without a car turned out to be difficult)

I filled the gap with epoxy in two stages (partly because my epoxy order was short one tube and getting some locally without a car turned out to be difficult)

sebastien
Sep 27, 2021

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These machine screws should really be flush so I can compress the butyl tape without the frame bottoming out so I carefully filed
them down.

These machine screws should really be flush so I can compress the butyl tape without the frame bottoming out so I carefully filed them down.

sebastien
Sep 27, 2021

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While the balsa was airing out and I waited for an order of epoxy I set to clean all the caulk residue from the hatch frame .

While the balsa was airing out and I waited for an order of epoxy I set to clean all the caulk residue from the hatch frame .

sebastien
Sep 27, 2021

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I got a huge garbage bag from the Alton marina to make a dust catcher attached from below with masking tape. (the Alton marina in Illinois is covered which is why I choose to do this project now.

I got a huge garbage bag from the Alton marina to make a dust catcher attached from below with masking tape. (the Alton marina in Illinois is covered which is why I choose to do this project now.

sebastien
Sep 27, 2021

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Yet another boater lent me this great little rasp bit that was exactly the right diameter (luckily I brought my drill)

Yet another boater lent me this great little rasp bit that was exactly the right diameter (luckily I brought my drill)

sebastien
Sep 27, 2021

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I took out all the rotten core until I hit dry balsa (as deep a one inch in a few places but mostly about 5/8).

I took out all the rotten core until I hit dry balsa (as deep a one inch in a few places but mostly about 5/8).

sebastien
Sep 27, 2021

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Because the hatch had also been caulked form the inside - and that had mostly held up over the years - water was getting trapped and rotted some balsa core.

Because the hatch had also been caulked form the inside - and that had mostly held up over the years - water was getting trapped and rotted some balsa core.

sebastien
Sep 27, 2021

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Another boater lent me this great little pull scraper to clean up the parameter.

Another boater lent me this great little pull scraper to clean up the parameter.

sebastien
Sep 27, 2021

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I think the reason it never sealed correctly (I'm guessing from the factory ) is that the machine screws that hold the hinges stick out about 1/32 -1/16.
When the hatch was tightened down the screws left a mark on the gel coat and stopped the hatch from fully compressing the caulk right underneath the hinges.

I think the reason it never sealed correctly (I'm guessing from the factory ) is that the machine screws that hold the hinges stick out about 1/32 -1/16. When the hatch was tightened down the screws left a mark on the gel coat and stopped the hatch from fully compressing the caulk right underneath the hinges.

sebastien
Sep 27, 2021

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first: clean up all the old caulk and muck

first: clean up all the old caulk and muck

sebastien
Sep 27, 2021

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S

The main hatch has has been leaking for a while but I wanted to get off the great lakes before taking it apart (I made a quick and dirty rain cover that attached into the four existing snaps for the sun shade)

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sebastien
Sep 27, 2021

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Album information

Category: Front hatch repair

Album owner: sebastien

Date created: Sep 27, 2021

Item count: 27

View count: 614

Comment count: 0

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