advice on re-core fuel cell hatch
 

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i had a fun day today, actually not to bad, thanks to some great advice from vic, did this in 1.5 hour with a $4.00 flapper wheel from harbor freight.

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was going to use foam like nidacore or divinicyl, but cant find it locally in less than a whole sheet. probably going to go back with plywood. whats a good one to use? the wood in there was 3/8, thinking about going back with 1/2 or 5/8.

Ideas?

Ferm did a write up on this several years ago.

Putting a "bevel" edge on the plywood will make getting the glass to stick without bubbles a lot easier around the edges.

I hinged mine to make access easy to the tank and fittings.

https://www.lowes.com/pd/1-2-CAT-PS1...4-x-8/50254847

$50....can't beat that

Just what im looking for, but currently not available at any store within 150 mile radius. Can get some exterior 3 ply locally

Phat, You look like you are going to perform a Hatchectomy (?)

The little roller they sell to aid in removing air bubbles and shaping the mat on contours is very helpful, and as far as the hatch holes ,it's important to keep the hatch flat when you apply the core but try not to let the resin-drip through the hole and seep back onto the top side of the hatch cover, I taped around the opening, good thing I did! Hope this helps some.

Are you going to do the little squares or one piece?

I'd be afraid that one piece would eventually warp, especially if you use 1/2" 3 ply pine. Might even twist when you wet it with resin or while its setting up?
Not that I know... I haven't done a full deck or large flat piece...yet...

Found local 4x8 i/2 kiln dried treated ply from local boat builder. $80. He'll sell me what i need , 30"x43". But its still $80. Probably gonna go with that.
Was thinking cabosil to bond wood to hatch, then seal all with couple of layers of 6 oz.

Any thoughts

I thought it was a little overkill, greyduk, but it sure saved a lot of itching.

Thanks for the tip,step. Was wondering how to avoid drips. Luckily i have a large piece of starboard to us as a work table and i have to repaint deck afterwards anyway.

Skunk, i was going to do one piece, I think this is at least 5 ply, not sure.

I did notice on the fishbox lid, they added a stiffener down the middle

made a little progress past couple of days. found some 1/2 marine ply, so went with that.

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even managed to get the "Ferm" bevel on it

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we are going out tomorrow, so needed a tempory hatch. this is some old 3/4 shelving i had in the shed.
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V20 looks good with a dance floor