Sloppy hatch install needs a fix

[Loki9]

A previous owner of my Pearson 30 replaced the forward hatch. The new hatch is slightly larger than the old one. Whoever installed it had to enlarge the hole in the deck and interior liner and they failed to clean up the edges and seal the gap between them.

The hatch doesn't leak and I don't want to remove it from the deck, but I would like to clean this up. Any suggestions on how to proceed?

[Summer Magic]

I would probably remove the rough edge with a grinder or dremel and then fill the gap with epoxy, then sand it down. Not the best solution bout it would improve the appearance. You could also frame it in with solid teak. That would look sweet!

[poopdeckpappy]

That's what I would do, grind, get some poly filler and spray a new finish on

not as easy as it sounds but doable and a fun project

[SloopJonB]

Originally Posted by poopdeckpappy

That's what I would do, grind, get some poly filler and spray a new finish on

not as easy as it sounds but doable and a fun project

Pappy is right. Putting teak trim up would require pretty advanced woodworking skill to make those large radius corners and it would only cover up that exposed core, which WILL get wet sooner or later (probably sooner since it is a hatch).

It's a LOT easier if you remove the hatch first - it prevents grinder marks on the hatch, gives you complete access to the surface, allows you to work from above (downhand) and you get to ensure it is properly sealed when you remount it. Consider the quality of work done on the original installation - do you trust their skill at caulking?

[PorFin]

Originally Posted by Loki9

A previous owner of my Pearson 30 replaced the forward hatch. The new hatch is slightly larger than the old one. Whoever installed it had to enlarge the hole in the deck and interior liner and they failed to clean up the edges and seal the gap between them.

The hatch doesn't leak and I don't want to remove it from the deck, but I would like to clean this up. Any suggestions on how to proceed?

My initial thoughts were quite in synch with Pappy's -- but after looking at the photo a little closer I'm now not so sure.

It looks like you're dealing with two distinctly different pieces: The cored deck, and the molded headliner. They've apparently cut the mounting flange off of the headliner (can anyone else see screw holes there, or is it just me?). If they are separate pieces -- and you want to keep them that way (like if you ever want to drop the headliner to access wiring or the like) -- filling/glassing the two together might not be the best idea.

Those gaps also look to be a little big for filler alone. A couple of layers of cloth under the filler would probably be in order to at least give a little strength to the repair.

[georgefmys]

If you can identify the hatch manufacturer,check with them. They will often have a trim ring and or interior screen frame that will do the trick.Ev en another company's trim ring can work if hatch is of similar size

[mitiempo]

It looks like a Lewmar. Their hatch trims are designed to be installed before the hatch itself.
Lewmar

[Loki9]

A trim ring, of course! That's just what I need. It is a Lewmar hatch.

[mitiempo]

Only problem, is that the cutout has to be a bit larger with the trim and the trim is installed first with the hatch overlapping it. Also, I just noticed, your hatch looks like a flat base hatch without the flange that fits into the cutout, but I could be wrong about that. It states that it will not work with that design of hatch.