[Public-list] Plywood Hatch Cover

[Jim Davis]

Not really too hard to do.  Cut three sheets of 1/4 ply larger than needed.  This can be exterior ply if you plan to paint the finished project or put teak on the top.  Trace the curve on 2 pieces of 2x6 pine then cut the curve with a band saw or saber saw.  Bend one oversize piece of 1/4 exterior ply and tie it down with drywall screws to both 2x6's.  The 2x6's re acting like your current end pieces.  Screws on the outboard ends only and put any filled knots facing up.  Then paint the surface with epoxy thickened with adhesive filler.  Paint the same epoxy on the second sheet of ply and lay it sticky side down.  Again screw it down on the outboard corners with drywall screws.  Make sure everything is tight.  Repeat the process for the top layer, only this time any filled knots down.  If you plan to put teak battens on, omit this sheet and glue the teak strips on instead.  Let the epoxy cure for 24 hours and cut the glued up ply with a band saw or very carefully with a saber saw.
Make your end and side pieces copying the old ones and hand fit the pieces.  Once it all fits smoothly (also fits the boat) Assemble with epoxy and screws.

Hugh and Roger have good suggestions.


Jim Davis
S/V Isa Lei
CT 35

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