Smoked Hatch Boards

I'm looking to replace my original 32-3 hatch boards with smoked lexan or similar material. Wondered if anyone has done this as a straight up replacement. I saw one thread wth a good looking smoked lexan and teak hatch. I'm trying to eliminate the teak so I'm hoping to replace the four piece teak boards with a four piece lexan set. Also wondered if anyone knew of some place that will make a hatch board set? Thanks!

Lexan and Acrylic are very easy to work with woodworking tools (circular saw and router is really all you need), so if you're inclined you could do it yourself. Just use your current boards for templates

or local shop...

Frank, I'd bet the local glass repair shop could do it for you...
Or your local Cabintmaker could do it as well.
As Nate said, the stuff is not difficult to work with, as long as you have the tooling.
Chris

I did the same thing as you. Although I ran into some hitches and in the long run got lucky. Called every glass company in the Ventura, CA area and finally got a guy who new the business and referred me to a plastics company in Camarillo, CA. The reason the glass companies could not help me was because 99% did not carry the thickness or the smoked lexan.

So what I did was bring the wood slats to them and they made them for me. Cost was around $200.00

Call a plastics company and they will direct you on what to do. Hope this helps!

Why are you trying to eliminate the teak? I doubt that plastic will be nearly as sturdy, particularly the interlocking edges which will be prone to chipping.

Try a local plastic supply house. We have TAP Plastics here on the west coast and they supply and cut it as well. Lexan will be very expensive in the thickness that you need. Trick will be not to have to buy a whole sheet. Lexan will be stronger than wood of the same thickness (like the the bullet proof stuff at the bank).
I have seen thinner sheets used with a wooden strip on each side to make it fit tight in the companionway grooves. Beware though, thick lexan will be very heavy, much more than the wooden hatch boards. You wont want to drop a piece of that on your foot....

Nice to get the additional light though.

If your looking to do the work yourself then you can order some nice stock from a company called US Plastics.

http://www.usplastic.com

The lexan sheet is listed under "polycarbonate sheet" and comes in smoke and bronze with UV resistance coating.

You'll like these guys for anything plastic

and as always. I have no affiliation with USP, just another satisfied customer

Mike T
E-29 Babylon, NY

Geoff - looking at replacing the teak boards for 2 reasons: 1 - don't want to maintain them. 2. - additional light below.

As much as I like the look of the teak on my 32, I'd be willing to get rid of it all if I could replace it with good looking alternatives. The hatch boards are on of the simpler replacements. Things like the hand rails or winch pads are a little harder to find good looking replacement materials. Although I spoted some good looking hand rails on an Island Packet at the strickly sail show in chicago. They had a similar shape to the original teak rails on our boats. My main reason for replacing exterior teak is maintenance. I don't want to spend one possible sailing day, varnishing or refinishing. Our season is short enough as it is. That said I'm sure many don't share my view on this and feel the maintenance is worth it.

Thanks for the responses, I'm going to try a local plastics company or us plastics and get a quote from these guys http://www.customsizes.com/. Found them while surfing. I'll see how the costs work out and go from there.

If anyone has replaced any other exteriior teak with altenate materials let me know.

Frank,

I have found that once I get the teak in good shape with Cetol, I can get away with a coat of Cetol gloss at the beginning of every season (takes about 2 hours). This is what it looks like:

http://www.ericsonyachts.org/infoexchange/showthread.php?threadid=511&highlight=traveler

As for the light, I never close the boat when I am in it. Actually I did once before I got a dodger and it started to rain. That's when my wife decided to start cooking onions.

Cetol

Geoff - I'm thinking I may end up going the Cetol route. Thinking about using the light colot and then the clear to get a look closer to varnish.

BTW - I purchased the stainless low profile vents from marniner hardware for the transom. Got a good deal at the strictly sail show. They came in today - things of beauty.

Those stainless cowl vents are pricey but really dress up the boat. Good move. Also, keep the teak! There is a reason why Hunters and Catalinas have no teak, but Tartans do.

Those cowl vents are beautiful, I'm just having trouble coughing up that dough until the plastic ones die. Frank I replaced all my exterior teak with SS and aluminum. Didnt have much anyway and I hate taking care of exterior woodwork....

Frank;

Three years ago I did exactly what you are proposing - for the same reasons. It was fairly expensive, but I ordered a 2' X 4' X 1/2" piece of polycarbonate from an online source (I think it was usplastics.com). Cut it on a table saw and finished it with a 2 HP router, using the original slats as a pattern. One note, tape the material heavily before using the power tools to prevent scratching.

The result is very sturdy (actually bullet proof!), watertight and looks great. The panels do scratch easily though, so you may want to consider vinyl storage bags. The 1/2" material is every bit as strong as as 3/4" teak.

It was also necessary to replace the vertical 'tracks' to accommodate the thinner panels. I made these from strips of 3/4" King Starboard using the table saw and router. I also added padeyes so that the panels could be attached to the boat to comply with the ISAF regulations for offshore racing.

Good luck with your project.

-Steve

Abi

I bought cowl vents from ABI in Petaluma, CA. Boy o Boy do they make a diference. The price was not bad and I talked my wife into them being a fathers day present. I think I paid about 90$ each. Made in China but what isn't today. Give them a call and tell them that I sent you. It won't make a diference but they may give me an even better deal next time.

Go for it. You only live once. An once you have installed them, you will feel like a million dollars.