This is a beautiful Shannon sailboat. The companion way hatch had little to be desired. It does now.

1. Some before pictures.

Old Hatch

2. Had a crack in it where the locking latch was bolted.

Old Hatch

3. Not shown is the work involved in making this flat 1/2 inch piece of solid fiberglass.

from scratch

4. A large mirror was first sprayed with a mold release and then 17 layers of mat and roven woven were layed up.

Building hatch

5. With the old hatch as a template the sides were cut off. Then with proper measurements the hole were cut out for windows.

hatch

6. The holes have been stepped down with a router as will the 1/2 inch plexiglas inserts that will fit in them. First layer of gelcoat is put on both sides.

Hatch

7. Another angle.

Building a Hatch

8. After sanding and polishing the gelcoat the top side is scuffed and sprayed with a gray non-skid gelcoat.

Building a Hatch

9. Non-Skid.

Building a Hatch

10. Now time to make some plexiglas windows.

Building a Hatch

11. Professional equipment for a pro job.

Building a Hatch

12. The rough cut. The edges are then sanded to remove any chips to prevent cracking.

Building a Hatch

13. The windows are put in with black urethane chalking and the old hardware is reused. Except this time the screws come up from the bottom into the tapped fiberglass and a little 5200. It has a much cleaner feel without all the screws coming down from the top.

Building a Hatch

14. Looks good on the boat.

Building a Hatch

15. A view from the cabin.

Building a Hatch

16. Different view.

Building a Hatch

17. Amazing how a simple hatch can really change the look of an already beautiful boat.

Building a Hatch