I opened up all areas that had fasteners, that?s a lot of holes. There was some localized core rot, more holes were drilled around those areas and all coring removed. Holes were filled with thickened epoxy or 8lb density foam in larger areas.
I glassed both sides of 3/4? piece of plywood core to fill hole. Once faired it was finished with a krylon paint job. High build primer filled by antique white top coat. Close enough.
It was a tight fit but happy with the result. This is the starboard rear transom hatch. I build a fiberglass bracket to install the Blue Sea battery combiner and on off switch
Installed the blue sea add a battery system. The switch is run in the on position, both batteries are charged when charging voltage is available. During discharge they are separated so your starting battery will not be drained.
Door is installed for test fit. I was pretty happy with how it turned out, not perfect but better than the old one. The green coating is the PVA, it washes off with water. Window was installed using the old door as a pattern.
Once the mold was prepped, I brushed on a Couple heavy coats of Gelcoat. 3 layers of Mat, HoneyComb core, three more layers of mat, Gelcoat. I laminated block of hardwood where hinges, door handle are mounted