Operation "Hatch Repair" underway
 

The weather was so pretty today, I shoulda put the boat in the water and went fishin', but I was in an ill mood (that means bad mood for all ya yanks) and I really didn't want to fight the idiots at the ramps. I decided it was a good time to get my repair started so it could be done by the long weekend.

Here is the object of repair, the infamous cover over the fuel tank. Squishier than Sponge Bob
http://i29.photobucket.com/albums/c2...y/100_0731.jpg

Access covers removed, eeeewwww
http://i29.photobucket.com/albums/c2...y/100_0732.jpg

Hatch off, eeeewwwww, what the hello is that crap?
http://i29.photobucket.com/albums/c2...y/100_0733.jpg

Re: Operation "Hatch Repair" underway
 

Cover removed and the damage (aft access hole)
http://i29.photobucket.com/albums/c2...y/100_0734.jpg
http://i29.photobucket.com/albums/c2...y/100_0737.jpg

Forward hole
http://i29.photobucket.com/albums/c2...y/100_0735.jpg
http://i29.photobucket.com/albums/c2...y/100_0736.jpg

Re: Operation "Hatch Repair" underway
 

A look at the construction, looks like a gel coat over resin and mat.
http://i29.photobucket.com/albums/c2...y/100_0738.jpg

At first this corner concerned me, but it is real solid. I may squirt some resin in the gap just to fill it.
http://i29.photobucket.com/albums/c2...y/100_0739.jpg
http://i29.photobucket.com/albums/c2...y/100_0740.jpg

Re: Operation "Hatch Repair" underway
 

The wood was totally covered by resin and mat, except where the access holes are cut out ( DUH ), water just got in and made a mess of it.

These pics are of the stuff I removed without help from any tools
http://i29.photobucket.com/albums/c2...y/100_0741.jpg
http://i29.photobucket.com/albums/c2...y/100_0742.jpg
http://i29.photobucket.com/albums/c2...y/100_0743.jpg

Re: Operation "Hatch Repair" underway
 

Time to bust out some power tools, I needed to knock the edge of the glass off where it went down over the edge of the wood so I could get the wood out.

Tools of the trade.
http://i29.photobucket.com/albums/c2...y/100_0744.jpg

After knocking the edge off and more hand work.
http://i29.photobucket.com/albums/c2...y/100_0745.jpg
http://i29.photobucket.com/albums/c2...y/100_0746.jpg

Re: Operation "Hatch Repair" underway
 

After using some putty knives.
http://i29.photobucket.com/albums/c2...y/100_0747.jpg

After grinding all the wood stuff off.
http://i29.photobucket.com/albums/c2...y/100_0748.jpg

Here is my replacement wood piece. I cut it so I had 1" of clearance all the way around the wood. The old lid had more like 2 1/2" all the way around.
http://i29.photobucket.com/albums/c2...y/100_0749.jpg

Re: Operation "Hatch Repair" underway
 

Notice I cut it at an angle, I am hoping this will aid in the transition with the glass mat. 35 degrees is what I went for.
http://i29.photobucket.com/albums/c2...y/100_0750.jpg

Just laid into the cover to see how I did. 1" all the way around.
http://i29.photobucket.com/albums/c2...y/100_0751.jpg
http://i29.photobucket.com/albums/c2...y/100_0752.jpg

That's it for today, I was all scratchy and wanted to get into the shower.

Re: Operation "Hatch Repair" underway
 

Nice job, this will be a really good tutorial. ;)

This must be a common repair for our year, I have to
do mine soon too.

Re: Operation "Hatch Repair" underway
 

I think it is common for all years that had the fuel tank there. The foam isn't helping anything, it just holds the moisture. Stupid foam. Makes me worry about the rest of the floor, but I haven't come across any more soft spots. I'm keeping my fingers crossed.

I have noticed that a few other areas need to be thought about though. My battery platform and trim pump platform has wood rot as well. They used some heavy duty glass in there, so they are still standing, but now that I have materials, I may just go ahead and cut them out and replace them. The bulkhead just in front of the motor well ( I/O ) needs to be replaced too, as the wood is just as slimy as snot, but I figure that to be a winter project.

I think there is a combination of causes for the hatch cover though, like is shown in the pics, the access cover holes were just kinda cut in without glassing the exposed wood, also, the screws holding in the access cover bezels were not treated with any kind of sealant, thereby letting moisture to get in there as well, and did I mention the foam? I'm gonna go through all the in deck fasteners and coat them with some 4200, hopefully its not too late ::)

Re: Operation "Hatch Repair" underway
 

Looks good!!

But if were me I be digging out that foam and checking out the gas tank, before it starts leaking!

You have it open, might as well keep going!