Shims for hatch

[jknappsax]

I'm redoing the hatch on my O'Day 32' CC, and the shims that curve with the coach roof and give a flat area to mount the hatch are pretty well rotted, and have been leaking for a long time (with the PO). I need to make new ones to mount the refurbished hatch and gasket, and I would like recommendations for what to use. I wanted something that won't rot, but none of the synthetics seem appropriate, but I don't know everything that's out there. As a last resort, I might use 3/4" marine plywood thoroughly saturated wiyh epoxy, but I thought maybe someone might have a better suggestion. BTW, I only need four pieces, about 24" long and 4" high, so any suggestions would be greatly appreciated.

[CapnHand]

Build it up out of glass and epoxy and then forgetaboutit

[sailingdog]

I'd second building it out of fiberglass and epoxy... very low maintenance, and relatively strong and inexpensive to do.

[jknappsax]

It looks like the nod goes to building the coaming out of glass and epoxy. Thanks for the advice!

[hellosailor]

jk, if you want to save some volume and money on those supports (I wouldn't call anything much over 1/4" thick a shim) you can use florists' foam to make a rough shape, then wrap it in epoxy glass to get essentially a hollow-cored beam shape.

Of course if you have to anchor anything into them--using lumber and wrapping that would work out better.

[sailingdog]

You say it is 24" x 4", but what is the last dimension??? Considering that you were going to us 3/4" marine ply for it, I'd guess that it is about 3/4" or an inch thick or so. But, if it is more than a couple of inches, then I wouldn't use solid wood for the interior, as that will be heavier than it needs to be.

I'd use the florists foam as HS has suggested for the bulk of it, and then use marine plywood on the bottom, or whereever the screws that are going to fasten it to the rest of the boat are going to go. Don't forget to pot the holes with thickened epoxy.

However, it really depends on how much of a load this piece will take and how heavy a laminate you plan on using to make it. If the piece is under heavy loads, then a solid wood filler might make sense.

[jknappsax]

I was just pondering how to make a mold to make this piece, but the florist's foam is a great idea. The part is only to level the area where the hatch mounts, so it isn't very heavily loaded. I will be removing any rotten core and filling with epoxy mixed with colloidal silica, so the area where the hatch mounts should be pretty strong, and I will , of course, thoroughly seal the mounting holes. I just finished a bottom job with MAS Epoxy, so I'm (entirely too) familiar with the concept of TOTALLY sealing the interior of the hull, deck, etc. to prevent future water intrusion. I even sealed the inside of the CB trunk. I appreciate all the good advice. I'm somewhat of a newbie at boat projects, but not a newbie to projects, so any seasoned advice is REALLY appreciated!