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!

Re: Operation "Hatch Repair" underway
 

What would I be looking for exactly? Corrosion? My luck, I'd cause a leak ;) There is no smell of gasoline ( yet ) so I'm inclined to not dig around too much. However, I don't like the foam being there. Dangit, now what do I do?

Re: Operation "Hatch Repair" underway
 

Well your right! If you start digging you might end up with a season stopping problem??

If there is no gas smell then just finish the hatch, and fish, But this fall remove the hatch and cover for winter to dry out the foam and plan on it being a winter project!

But its something that needs to be done! Don't let it go to long!!

Re: Operation "Hatch Repair" underway
 

Let all the foam DRY OUT B4 ya reinstall the deck...w/it replaced and sealed properly, it shouldn't get moisture back in it ;) ...

Re: Operation "Hatch Repair" underway
 

looks great just leave the foam in and have a good season without other issues

Re: Operation "Hatch Repair" underway
 

Frayed, Great job, cant wait to see the rest of the work and the copleted project. Your doing good, keep on truckin. ;)

Re: Operation "Hatch Repair" underway
 

One question. with the wood coming within an inch of the edge, will the hatch go back in place? Pretty sure it will, but check it before you glass it in.

Re: Operation "Hatch Repair" underway
 

I's thinkin' the same thing ;) ... and I commend yer work FK ...looks like some good stuff goin' on there 8) ...

Re: Operation "Hatch Repair" underway
 

hey Fray i can measure my 78 hatch to see what it has for spacing on the edges of mine.

Re: Operation "Hatch Repair" underway
 

There is a 1" lip all the way around the deck (see it in the pic), That's why I went with a 1" gap. Keep in mind, that the gap will be larger by the time the edge gets to the lip (angled cut). It looks like the edge of the cover just rests on the lip. I should have plenty of room. I could just sink some screws into the screw holes for the access covers and set it in place before glassing just to make sure. Thanks guys.

Re: Operation "Hatch Repair" underway
 

Just out of curiosity, how much will the completed project cost you?

Re: Operation "Hatch Repair" underway
 

Looks good. Next time if you take a router and lower the bit about 1/4 inch and run it a round the edge of the wood then you can pull off the inner skin in one peice. Thats wht I have done and it seemed to work very well without all the grinding.

Does anyone know why Wellcraft uses these little 6x6 sections of plywood?

Re: Operation "Hatch Repair" underway
 

They must get it for free. But you'd think all the time to cut and place all the little squares would make it more costly.

Didn't they realize that was a bad idea? ::)

Re: Operation "Hatch Repair" underway
 

Good question. Here goes...1) resin and hardener, $20.00 (thanks Skools and Parker Boats) 2) Fiberglass Mat $0.00, it's good to know people that work at Hatteras Yachts 3) plywood $46.00 at Lowes, 4) dust masks, brushes, measuring cup and other misc stuff, $20.00. So far the grand total is $86.00. Just add labor (free cuz I'm doing it for me) and that is a real reasonable price for a repair.

Re: Operation "Hatch Repair" underway
 

I dunno, but that engineer needs his head examined. Every place that was cracked was right at a joint, go figure.

Re: Operation "Hatch Repair" underway
 

There wood in that there foam!

I was contemplating the whole foam thing, so I went and sat in the boat staring at the mess. I thought there was some wood cross supports somewhere in there, I mean who would just want to put all the weight transfer directly to the tank? Sure enough, I caught a glimpse of some wood and started digging around. I found 2 cross supports. They were totally soaked. Aww hell, I might as well dig 'em out so they can dry off.
http://i29.photobucket.com/albums/c2...y/100_0754.jpg
http://i29.photobucket.com/albums/c2...y/100_0755.jpg

I removed at least 70 lbs of soaked foam. As you can see it took a good majority of the zinc chromate primer with it. I suppose I could clean it up real good and hit it with some other type of aluminum primer, being as zinc chromate is illegal nowadays. The good news is no sign of corrosion on the top of the tank ;D

Re: Operation "Hatch Repair" underway
 

Funny as hell when ya stated how you sat on the boat and stared at it. I do it all the time myself, hoping things might repair themselves. ;D

Re: Operation "Hatch Repair" underway
 

LOL, yeah, I do it to contemplate my next move. I like to think things through first. I am waiting to borrow a jigsaw from a buddy, that's why I didn't do anymore work on the hatch cover. I felt like I needed to do something for an hour. This fit the bill nicely.

Re: Operation "Hatch Repair" underway
 

Most boat builders back then bought scrap wood at yards and used them to build the caps and decks. it was cheapest way to build them. Also they had alot of scrap wood laying around back then from their molds frames. most all your 1973 to 1985 boats had that in the floors it slowly change over in alot of lines over the years to now but astill some do that to their caps and decks.

Re: Operation "Hatch Repair" underway
 

Very nice, and know you have me thinking about my tank and cover..... Some one please stop me!!!

Re: Operation "Hatch Repair" underway
 

frayed, i removed & replaced the wooden braces on my tank. they were just sitting on top of the tank and held in place with the foam. if you do that, make sure the treated wood does not touch the tank, the chemicals in the wood will cause corrosion with the coating on the tank. i also cut some strips from an old boogie board and placed on top of the wood strips so the hatch sets slightly raised and when tightened down, it compressed the foam and gives a good snug fit. now is also a good time to redo the fastners, i did away with the screws and replaced with threaded screws and nuts

Re: Operation "Hatch Repair" underway
 

Now Phat, you know this needs 'splainin. What kind nuts in this blind application?

Thank you for your attention to this matter sir ;)

Re: Operation "Hatch Repair" underway
 

If you dont smell gas, DO NOT REMOVE THE FOAM !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! It is a pain in the arse. Trust me , i pulled all my foam out . Huge job. Plus the replacement foam is very expensive. What your doing looks good though.

Scott

Re: Operation "Hatch Repair" underway
 

Phat, I'm wondering the same thing that Air mentioned. How would you use threaded screws/bolts and nuts?

Fray, my hat's off to you buddy. Nice work so far. Thank you for posting the step by step process. As said earlier, this thread (because of your attention to detail) will prove to be very helpful to many guys down the road.

About the cross supports, what's the difference between the direct transfer of weight from the cover and the transfer of weight to the cross supports that rest on the tank? I could see a difference if the cross supports were tied into the stringers or something, but as long as they're just sitting on the tank, do they really help? Just asking...

Re: Operation "Hatch Repair" und
 

HUCK nuts or spack nuts would work in an application like this.

http://www.sweethaven02.com/Aviation...l0992a0022.gif

But, you need special tools to install.

Another option would be the clip nuts used in automotive applications.

http://www.hammondmfg.com/1421npic.jpg

Re: Operation "Hatch Repair" underway
 

frayed, the reason I asked about the cost of repairing,
is because I was looking at the King Starboard site
and found some anti-skid board, they recommended a site
for purchasing and I checked .
Here is a link to what I found:

http://www.marisafe.com/Store/viewIt...;FLT=358051379

I wonder if a piece of this could be modified and dropped right in place?

nightly repair porn
 

Aiight fellas, the next installment.

I had to borrow a jigsaw to cutout the holes. It's not my fault they are not round, I used a pencil to scribe the holes from the cover, that is how they cut it ;)
http://i29.photobucket.com/albums/c2...y/100_0756.jpg

Here is the cover with some plastic wrap over the holes (to keep the goo contained)
http://i29.photobucket.com/albums/c2...y/100_0758.jpg

And flipped over and acetone wiped.
http://i29.photobucket.com/albums/c2...y/100_0759.jpg

Re: Operation "Hatch Repair" underway
 

I didn't have the ability to get any pics of the goo going on, sticky stuff and cameras just don't go together. But here is the final product of tonights episode.
http://i29.photobucket.com/albums/c2...y/100_0762.jpg

Anything that has weight that I could find, or could hold water got piled on. Lower left corner, see that? That is an isolation transformer. Got a car battery, oh and an electric motor on there too. ;D
http://i29.photobucket.com/albums/c2...y/100_0761.jpg

Re: Operation "Hatch Repair" underway
 

If you needed 700 lbs of ballast, you could have just invited a few of our more portly members over ;D

Re: Operation "Hatch Repair" underway
 

Yeah, but I don't want them hanging out for a week ;)

Re: Operation "Hatch Repair" underway
 

He would have to buy all Pepsi's all week!