May, 2004
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Quarter Berth Hatch Replacement
Broken old quarter berth hatch, at the factory in 2000 with the new traveler installed over the top
Old hatches in 2002 after installation of the dodger, the galley hatch is closest to the camera, the quarter berth hatch is just behind it on the right, and the companionway sliding hatch cover is on the left
On a boat, everything's a compromise. Back when we bought SolMate we shipped her to the Valiant factory in Texas for heavy-duty body work. Part of that work was shortening the boom and moving the traveller from the back of the cockpit to the coachroof. The new traveller obstructed the quarter berth hatch, and it could only be opened about four inches.
Obstruction wasn't the only problem. When Stan visited SolMate at the factory, he heaved on the hatch, and the dried out teak split apart above the hinge rather than open. And it leaked. All in all, that hatch has been screaming to be replaced.
A few years back, Stan replaced the V-berth hatch with a Bomar brand, low-profile hatch. We haven't been thrilled with it, one of the arms broke a set pin and the handles are flimsy. So we ordered a Lewmar brand for the quarter berth replacement.
A quarter berth hatch came as an option with the Valiant 40. It wasn't molded into the deck when it was laid up at the factory like the other hatches, it was built of teak and added after the molds were removed.
The Lewmar hatch was sized to be small enough to open in front of the traveller, not so small air wouldn't circulate.
View of the inside of the old hatch looking forward
Same view with the hatch and part of the frame removed exposing the deck core
Removing the teak frame from the hatch opening
Frame completely removed and checking for new placement
The deck is 7/8 inch thick. Here a sheet of wood has been attached underneath as a support while the deck is being rebuilt.
The side piece of pre-fab was installed after the back support was removed. The little side piece was also bolted to a supporting slab of wood while it was being glassed in place.
A pre-fab piece of fiberglass was installed as the bottom layer, basically the quarter berth ceiling. The bolts secured the glass to the wooden support during installation.
The ceiling panels epoxied into place with the little side piece of plywood still bolted to the little fiberglass side panel
Preparing to cut the plywood frame, which will provide the new hatch a leg to stand on, on the galley "workbench"
A core of end-cut balsa was laid over the fiberglass sheet, then the new frame was epoxied into place.
Top slab of fiberglass epoxied on, faired out with filler
Painted deck and fit checking the hatch before drilling the bolt holes, which will be through bolted
Fitting the teak trim, inside, with removable screws
