Custom Made Hatch Covers

[bruceboyles]

I have recently transported a 1975 Cal 2-27. Everything arrived but the forward hatch cover. Does anyone know if/where I can find such an item or know of someone who makes hatch covers?

[JimsCAL]

Hatch cover was there at the start of the delivery but missing at the end?

Doubt you will be able to find a replacement part for a hatch that old. Best bet would be to measure the size and replace with a new hatch.

[bruceboyles]

Well, all of the hatch cover started and most of the hatch cover did not arrive. A tiny fragment hanging to one hinge is all that's left.

The problem with new hatch covers seems to be they are all oval or rectangular. This hatch is trapezoidal.

[SJ34]

If you are talking about a canvas cover they are very easy to make. I just made two hatch covers, 4 winch and a binacle cover with $32 worth of Sunbrella fabric. Doesn't get much more custom than that.
BTW, I used a non-commercial sewing machine with a #18 needle and Sunbrella thread.

[bruceboyles]

Thanks for the suggestion. The original hatch cover was fiberglass. I don't think canvas would work, it would be too easy to step through.

[paul323]

Depends how handy you are. You could probably make one out of plywood, covered with a layer of fiberglass. Or you could make a wooden mould, cover it with wax, and make your own fiberglass replacement.

[Faster]

Unless you got really lucky at some yard wrecking boats, or a marine consignment shop I think Paul323 is on the money. For something like that it wouldn't actually be too difficult to make a temporary mold and make yourself a new one out of F/g... could be a fun project. You could even leave the middle part ungelcoated (as the original probably was ) to let in some light, or make provisions for an acrylic insert.

That's the route I'd take, anyway.. sounds like someone forgot to secure the hatch and the 'apparent wind' going upwind at 50 knots tore it off....


Of course you could also cut out the original altogether and install a larger, factory made Lewmar or Bomar hatch at some considerable expense... unless you can find a good one used at one of those places mentioned above.

[SJ34]

Originally Posted by bruceboyles

Thanks for the suggestion. The original hatch cover was fiberglass. I don't think canvas would work, it would be too easy to step through.

Sorry I thought you needed a hatch cover, you need a hatch.

Paul323 has the idea. Possibly make a hatch mould to fit your opening using door skin or ply, fillet the joints and smooth the inside with plaster, fairing compound or anything else that can be worked and sanded to a perfect finish. Apply wax or release agent and lay up the hatch as you like.