V-berth hatch cutting tool

F

Finally2

Member
Hey ya’ll!
I’ve searched and read soooooo many threads on cutting into the v-berth. I don’t see anybody explaining what tool they used. A router makes sense but even being careful they can jump and ruin such a delicate project. A saw as seems to bulky, the glass seems too thick for a dremel. A jigsaw seems ideal but then ya can’t get the beautiful rounded corners ya’ll have? I would love to use my cut as the lid if possible instead of plywood.

Any ideas? Thanks for any pointers! I’m doing it this weekend and am quite nervous
 
We used a drill for the pilot hole and then a jigsaw with a metal blade to cut out our hatch covers. The corners are well rounded and the cutouts made great lids. Judy did the cutting as she is really skilled and fussy with the jigsaw. The big job was left to me to remove the foam. About 8 big garbage bags full. Great project once it was done, as it really reduced clutter in the boat. It also makes the boat ride better on plane as the boat feels more balanced with the extra weight in the bow area.
 
I forgot to add that once you marked out your cutout line, we made a template, cover the cutline line with masking tape as this will reduce cracking on the clear coat. Wear and dust mask and have a vacuum cleaner nearby or on while you cut is even better. We also installed two hatches for side entry in the space where the portapotty goes. We used marine hatches for this, very handy for easy access of common items without lifting the mattress. I tried installing a wood frame to hold the top hatches with epoxy and screws from underneath, but this did not hold. So I used stainless steel screws from the top.
 
Thanks everybody! Glad to hear the jigsaw turns the corners fine! It’s definitely my preference. I want to use the cut outs as well for the lids. I also am nervous about the epoxy wood holding. My buddy swears it’ll be strong enough but the piece of mind of machine screws with nylon nuts on the backside seems like the way to go. I weigh about 220lbs and often climb out the front to secure the anchor and would hate to accidentally fall through
 
I prefer a 1" to 2" hole saw for the corners. I have used a jig saw, with various types of blades, including tile cutting--which can work well. I have also used a rotozip (or similar) with carbide 1/8" bit. Also the oscillating multi-tool (Fein Multi-master or Dremel, DeWalt, Ryobi, PC, Milwaukee, Bosch etc,)

The carbide--or diamond blade in the Multi-tool-is best. Bosch makes a good carbide semi circular or 1 1/4. I have used all type.

A spade bit helps to break up the foam. I have an 1 1/2" on an 18" shank. (as well as several shorter ones.)
 
Alright so I’ve opened her up. TONS of spray in foam. I’m about 2/3 way from total removal. Do you guys have any insight on tips for removing this wax/resin coating the hull?? I can scrap it off with putty knife but there will still be this residual stickiness. Would acetone be a bad idea?
 
Finally2":9fj3sp22 said:
Maybe just cover that sticky with a glass paint? If it would even stick?
Click to expand...

Acetone works great, lots of ventilation and respirator with voc cartridges. Pretty confined space in there!
 
Acetone did not work great. Most success came from an acetone wire brush drill bit and it cleaned off about 2 square inches and the wire drill bit was so saturated with the resin it was rendered useless
 
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