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Old 03-15-2007
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Replacing crazed lexan hatches - updated question

In an earlier thread, the question was asked how to replace crazed lexan glass on Lewmar hatches (see Hatch Glass Replacement). In this same thread, a Lewmar-certified shop, Select Plastics, in Connecticut was mentioned and I called them. But, I was shocked by the cost, approximately $300/p 22x22" hatch. I have 3 hatches. Ouch.

I'm sure this company does great work, but my question is this: couldn't most any glass company do the same thing with lexan or should I bite the proverbial bullet and just pay?

Thanks, Bob
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Old 03-15-2007
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Ouch

Shop around, look at local glazing companys and or do-it-yourself, if you use the smoked Lexan it is truly forgiving make a pattern and cut the plastic to match make a mould and radius it to fit your current configuration place in the oven @ 200° till the plastic relaxes and let cool naturally at the prices you quoted you could get enough practice to become an Expert

Fair Winds,

Bill
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Old 03-15-2007
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Ouch... I don't see why you couldn't just get the lexan cut to size by any competent glazier. The fitting and installation of it will be a bear, but nothing beyond what most competent sailors are capable of handling. Unless the lexan has some significant curvature to it, it really shouldn't be that difficult or expensive.
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Old 03-16-2007
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Most ports are convex and not flat, this is done to facilitate the shedding of water particularly on the deck skylights. Boatlife caulk should be used to bed the new Lexan. To remove the lexan utilize a piece of music wire and manipulate it thru the old caulk and with a pair of vise grips on each end of the wire you and an accomplice can use a sawing motion to remove the old port.

Fair Winds,

Bill

Last edited by Bill Mc; 03-16-2007 at 09:25 AM.
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Most ports may be convex, but most hatches I've seen that are lexan or acrylic are flat, or very close to it.
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I need to replace my main sliding hatch. It is about 1/2" thick and is curved, about 3/8" in 30". It does not sit in a frame just slides in the rails.

I was planning on checking with a glass shop, but would heating the new one then clamping it to the old one to take the shape work? Any suggestions ?

Gary
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If it doesn't have a frame, I bite the bullit and pay the $300.00. If the edge curves a fraction you'll have leaks.
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The SailNet store carries Lewmar hatches. Size 60, which is 22 11/16 x 22 11/16, possibly the size you're looking for, is listed at $398. Here's the link: http://shop.sailnet.com/product_info...oducts_id/3924.

Although I have not worked on Lewmar hatches, I did build 6 new hatches for my boat in 2003. If you use Boatlife Life caulk, as recommended previously, and you're careful, you can probably replace the lexan (or use cast acrylic instead of lexan) yourself and have a leakproof job.

Good luck.
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Sailingdog,

You got me. I was so caught up in my own evolution that I have just completed, that I didn't comprehend the question. Maybe I can redeem myself. If its just the flat Lexan that goes on top most companionways. Its pretty straight forward any glasier should be capable of replicating it. To do it yourself. Cut out the same shape/size hatch, the radius of the edges can be accomplished with a router, you need a sharp cutter and a mist of coolant to prevent smearing the material and then polish this edge with a cloth wheel and rouge. I hope that helps...

Fair Winds,

Bill
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Quote:
Originally Posted by Gary M
I need to replace my main sliding hatch. It is about 1/2" thick and is curved, about 3/8" in 30". It does not sit in a frame just slides in the rails.

I was planning on checking with a glass shop, but would heating the new one then clamping it to the old one to take the shape work? Any suggestions ?

Gary
What kind of material? Lexan?
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