1981 22 Classic Deck Hatch Installation

V

vancouverdory

New member
Hello Everyone,

We have just bought a 1981 C-Dory 22 Classic! One of the first projects we want to do is add a front hatch above the V berth like the ones on the newer models. We have purchased a hatch (about 17x17 inches) and plan to install it soon. As you probably know, the area where the hatch is installed on the newer boats is curved on the classic. We are just looking for any pointers or recommendations that might make the installation process easier. Anything is appreciated! The general plan as it stands is to cut a hole to match the inside edge of the hatch, removed some fibreglass/wood to make a flat surface for the flange of the hatch and then epoxy and screw down.

Thanks in advance,
James
 
vancouverdory":v21gu2hb said:
Hello Everyone,

We have just bought a 1981 C-Dory 22 Classic! One of the first projects we want to do is add a front hatch above the V berth like the ones on the newer models. We have purchased a hatch (about 17x17 inches) and plan to install it soon. As you probably know, the area where the hatch is installed on the newer boats is curved on the classic. We are just looking for any pointers or recommendations that might make the installation process easier. Anything is appreciated! The general plan as it stands is to cut a hole to match the inside edge of the hatch, removed some fibreglass/wood to make a flat surface for the flange of the hatch and then epoxy and screw down.

Thanks in advance,
James
Click to expand...

You could make a wooden frame or maybe AL that is flat to mount the hatch. Cut the deck and install the frame then put the hatch on top. The thickness of the frame is such that it spans the curvature you are covering. This means that the frame will stick up above the deck a bit at the lateral edges and stick out below the interior roofline on the longitudinal edges. You could relieve the interior side of the frame to match the roofline if you wanted to.

The key is not to have any depressions or recessed areas on the exterior surface where water could collect and stand.

Some people have done the equivalent thing for mounting their rooftop airconditioners.
 
Build the edges of where the frame will site up with strips of fiberglass tape. Then gelcoat to match then rest of the deck-if painted, then paint with the same color. I have done this with a number of hatches on fiberglass boats thru the years.

Here is an illustration as I did it on the Tom Cat 255 for the Air conditioner. Thataway_airconditioner_hatch017.sized.jpg


Thataway_airconditioner_hatch021.sized.jpg

In your case you will want to round the corners. This illustration matched the gasket of the air conditioning unit. This, plus a wooden frame inside, made the roof stronger. If there is a core, that core should be routed back about 1/4" and filled with thickened epoxy. When you put screws into a cored laminate, you want to over drill the holes, route out some core around the edges, fill back with thickened epoxy and screw/bolt thru this epoxy plug--again to avoid core damage.

The post 1987 boats have some camber to the roof of the cuddy, but there is a molded in flat bevel for the hatch to bed onto. Be sure that the hatch is big enough that your can exit thru it. This is a safety feature.
 
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