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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).
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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 .
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.
Yet another boater lent me this great little rasp bit that was exactly the right diameter (luckily I brought my drill)
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).
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.
Another boater lent me this great little pull scraper to clean up the parameter.
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.
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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).

  • Media owner sebastien
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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).
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Front hatch repair
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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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