Rebuilding the hatch cover (coffin lid)

[doug mayer]

Hatch cover on my boat is sagging at center and squishy soft as well.  No sign of any caulk or bedding on either of the inspection plates.  Removed the bottom fiberglass layer and found 3 strips of plywood, each 9 and 7/16" wide the length of the lid. Dry around the edges and sopping wet in the middle.  Why did they build the hatch cover this way?  Wouldn't the cover be stronger if two or three sections were set up crosswise rather than lengthwise?
I will try to follow the instructions to get some photos up.

[RickK]

We've seen some weird things on some of these boats. What year is it?  When Aquasport started getting into financial trouble they cut some corners.

[wingtime]

What year is it?  Also it may have been recored in the past.  Usually they are one piece of plywood or they can be a patchwork of plywood squares.  Remember in a layup like that the strength of the panel comes from the bottom layer of fiberglass being placed in tension and the core (plywood in this case) is just a spacer.   This is why a foam cored surfboard can be so strong.

[doug mayer]

There is now a photo in the gallery.  Maybe I will figure out how to put them on the forum page, but not yet.  Commentary also by the photo.

Removed the gas tank today, and there is no evidence of gas outside the tank, for which I'm grateful. Fuel hoses are original, what's left of them, from 1988.  Fuel feed hose has 1987 on it. Kinda brittle.  I think replacing the fuel feed hose is gonna be a challenge.  I'd appreciate any wisdom on that project.

[Capt. Bob]

Mod Edit:



coffin lid for \'88 Osprey 200. bottom is fiberglass--removed and waiting for reconstruction. plywood is 3/8", 3 strips each the length of the lid. wood around the inspection plates soaking wet, rotten (No evidence that any bedding compound was ever used when the boat was built).

Plan is to replace w/ 1/2" marine ply, and reconstruct using original top (deck) and bottom.  Likely will have to fare down the edges so the lid does not stand proud of the rest of the deck.  Also will add Strongwell angle (like angle iron) across the bottom where the helmsman stands to strengthen that.

Original gas tank (aluminum, 48 gal) is out, and may be salvagable. Film at 11.

Mod Edit:
You've done the hard part (it's not really) Doug, now just click on your pic in your gallery and you will get a box on the right side. A lot of options/info in the box labeled "Photo Details".  Click (right click gives cut and paste option, left click requires old school shortcut of "control c for cut") on the blue highlighted box next to "Linked Image" and you can then paste the photo in your post.

Good luck.