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Old 01-06-2022, 02:50 PM   #1
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Default 4600 rear access flip up hatch repairs

My rear access panels for the water and shore power are cracked. I was thinking they were fiberglass, but really they're Acrylic!!!

I was hoping I could just epoxy, glass and gelcoat like a normal boat repair, but I've been emailing TotalBoat and they're basically saying Epoxy/Glass may or may not work.

Boat Outfitters is to $$ and some say a plexiglass shop can make something. I'm more thinking making a mold off the top and building two new panels from the mold template.

Any one have experience with repairs on these panels or Acrylic? I'd rather epoxy/glass/gelcoat it if the repair would work

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Old 01-07-2022, 12:36 AM   #2
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A plexiglass shop is probably the best bet. They should be able to make ones that will be a perfect match.
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Old 01-09-2022, 02:10 AM   #3
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I ended up making a mold out of the existing non-cracked one. Even plexiglass would need to be painted since Gelcoat doesn't work on plastics that great.

I'm going to remake them in fiberglass.

Going to lay out chopstrand matting, then 2 layers of 1708 thick mesh... then 1/4 9or maybe 3/8 plywood, then three more layers of mesh.

Lots of sanding ang gelcoat and "hopefully" I get a decent result (=

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Old 01-13-2022, 10:13 PM   #4
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Well, the mold worked so far...

I ended up putting the 2nd coat of Gelcoat down too soon (step 1 of the mold before Resin and mesh) which caused those bad pits in the top "mold gelcoat" but some sanding and fresh gelcoat will fill that all in.

Next is sanding it down, fairing, sanding, more fairing, sanding then HOPEFULLY Final gelcoat and wet sanding.

Then if this isn't an utter mess, molding the other panel.

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Old 01-16-2022, 05:08 PM   #5
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Looks great! Awesome job
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Old Yesterday, 09:48 PM   #6
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Both pieces are out of the mold and roughly sanded.

Just need to clean up the panels with some filler, gelcoat and wet sanding. Need to check the fit on the boat this weekend before putting that effort in though!

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Old Today, 03:26 AM   #7
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They look amazing! Great work! Can't wait to see them on the boat!
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Old Today, 03:33 AM   #8
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Quote:
Originally Posted by dbriceno View Post
They look amazing! Great work! Can't wait to see them on the boat!
Thank you!

Doing a test fit tomorrow, if the fit is good, then I can start the finishing on them! 3 months until splash here in upstate NY...
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