35-2 Hatch replacement: Anyone with Photo's or suggestions?

[robjpowell]

We need to either build new wooden hatches for our 1976 35-2 or alternatively, replace them with a more current and appropriate design. Does anyone have any suggestions, and ideally photo's, from their own repair job? Any suggestions are appreciated.

Thanks
Rob

 

[ignacio]

Build new

Hi Rob,

I've been going back and forth with build vs. buy myself, and finally decided to build. The Lewmar hatches look great and are water tight, but would have required a bit of work to make them fit correctly. And they're pretty expensive.

I've decided to make my hatches like post #31 of this thread:
http://www.ericsonyachts.org/infoexchange/showthread.php?4959-WANTED-E29-Hatch/page3

I've actually made this previously when I had my E27 a few years back, and now my E35-II will get them. I currently have the frame built and assembled for the front hatch...just needs a little sanding and varnishing before I insert the lens. I have the main salon hatch started.

Teak isn't cheap, but it's far less expensive than the Lewmar hatches and I enjoy working with it.

We need to either build new wooden hatches for our 1976 35-2 or alternatively, replace them with a more current and appropriate design. Does anyone have any suggestions, and ideally photo's, from their own repair job? Any suggestions are appreciated.

Thanks
Rob

 

[ignacio]

Front hatch

Here is my current progress on the smaller front hatch. The top frame is secured to the lower frame using half-lap joints and #10 screws. I used thickened epoxy to fill gaps. I'm using epoxied teak plugs to hide the screw holes.

 

[Martin King]

Does anyone have any suggestions, and ideally photo's, from their own repair job? Any suggestions are appreciated.

Here's my replacement forward hatch:

 

[KWay]

Hatch Replacement E39 with Lewmar Ocean series

Both wood hatch have been replaced doing the same process.
Step1: inter wood frame removed
Step2: Fiberglass top edge cut off.
Step3: Inter wood frame trimmed and re-size.
Step4: Form made from tape / Glass cloth 6x Installed (West Epoxy)
Step5: Fairing Compound (West Epoxy)
Step6: Paint
Step7: Install Hatch
Please Note: This is just a overview of the process............