Galley Hatch Screw Up!

[Sam I am]

Wow, that's a lot of work getting that sheeting off, but it's probably the only way to get it to fit right! I built mine as if it had no hatch, then cut the hatch free. No problems - perfect fit! I also used the 1/8" Baltic birch plywood for sheeting. It works great!

Sam

[RunnerDuck]

Wow, that's a lot of work getting that sheeting off, but it's probably the only way to get it to fit right! I built mine as if it had no hatch, then cut the hatch free. No problems - perfect fit! I also used the 1/8" Baltic birch plywood for sheeting. It works great!

Sam

Mine fit perfectly as well before I took it off the TD to put the outside sheeting one. That's when I ^&#$@^& it up! I learned a huge lesson and will post my solution as I go along.

Thanks for the comment,

[tony.latham]

OUCH. I've got virtual blisters and dull tools now.

What did you think of that glue?

Tony

[RunnerDuck]

OUCH. I've got virtual blisters and dull tools now.

What did you think of that glue?

Tony

You're right Tony, I trashed a chisel getting the plywood off because I kept hitting nails but no blisters

If the glue is put on correctly and compressed between the two pieces of wood it's tenacious but if it's not compressed it's not very strong. I found areas that weren't all that compressed and the plywood came off pretty easy which isn't a good thing unless you're trying to remove it.

I certainly have learned a lot in this exercise.

[RunnerDuck]

Kenney, peel it & set the skin with the hatch in place. There's really no other way to be sure it will sit properly to seal, unless you make a jig to act as a form when adding the skin. Even though I had more ribs, I still didn't trust having it sit on the bench when putting on the outside skin. Any slight movement will cause a bad seal.

I'm a fan of skinning the hatch in place.[/quote]

Tom, I've got some questions about your method.

Looking at your pictures why did you stop half way down and not skin the whole hatch at once?

I see you have screws going straight through the skin in the cross members but through cauls on the sides and one cross member. Any reason for this?

I just want to get a good understanding of your process before I proceed as I really think your way of doing it will work best for me.

Thanks,

[aggie79]

Great "save" on the hatch. I can't even imagine how much work it was to remove the skin.

The reason that I skinned my hatch in sections is because my hatch is very long - about 6' from hinge to bottom - so I couldn't use a single sheet of 3mm ply.

Regarding the screws for "clamps" initially I didn't use a ply backer or caul. Later I became concerned about getting an even glue joint so I started using backing materials.

The screws I used were square-drive, washer-head, self-drilling "Kreg" screws. The washer head spread out the clamping effect and the self drilling part saved time since I didn't have to pre-drill screw holes.


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[RunnerDuck]

Great "save" on the hatch. I can't even imagine how much work it was to remove the skin.

The reason that I skinned my hatch in sections is because my hatch is very long - about 6' from hinge to bottom - so I couldn't use a single sheet of 3mm ply.

Regarding the screws for "clamps" initially I didn't use a ply backer or caul. Later I became concerned about getting an even glue joint so I started using backing materials.

The screws I used were square-drive, washer-head, self-drilling "Kreg" screws. The washer head spread out the clamping effect and the self drilling part saved time since I didn't have to pre-drill screw holes.

Thanks Tom, I appreciate that. My plywood should be in today so will start skinning again later today or tomorrow using your technique

Stay tuned,

[RunnerDuck]

TADA!

Good news everybody, I now have my galley hatch skinned with 1/8" plywood. After a couple of false starts like cutting the plywood the wrong direction, I put the hatch on the TD to make sure it fit perfectly and then put on the plywood.

I attached the plywood along the top with the temporary hinges and a few screws.

Hatch Skin 1.jpg (238.73 KiB) Viewed 698 times

Then I glued the edges and braces with lots of PL adhesive.

As suggested I clamped it all down with cauls and lots of screws. I let it cook over night.

Hatch Skin 2.jpg (266.42 KiB) Viewed 698 times

The next day I trimmed the edges with a router and by golly it fits perfectly

Now I'm ready to glue down the .032 aluminum skin on top of the plywood. I think I'll use contact cement and roll it in place.

Thanks to everyone for their comments and support. I really appreciate it and certainly saved the day.

Now to the side skins and the roof!

[Alan_H]

Hooray!!!

Glad it worked out for you without having to start from scratch!

Now it's time... as Stumpy Nubs would say... to sit back and have a cold one, 'cause you deserve it.

[tony.latham]

The next day I trimmed the edges with a router and by golly it fits perfectly

I suppose the moral of the story is to always-always listen to the wife.

Tony

[aggie79]

Fantastic! Well done. I know that is a relief.


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