McKee Craft 14: Hatch lid replacement

The original lid, underside view.

The hatch lid that came with the boat is intact.  It was not attached.  It is in great shape but is exceedingly heavy.  The ply core is visible in one corner and doesn't appear to be waterlogged, but it must be.  It feels like it has a lead core.  We will stow it away under the house and deal with it later.  To build it's replacement, we went with a veneered marine ply, some bits of mahogany for the weather lip and a skin of 8oz glass set in West system epoxy.

Here are photos of the steps with captions.

The underside of the new lid prior to epoxy and varnish.

Corner lip detail on the underside of the new lid.  We traced the shape from the original lid.  After the glue set, the jig saw was used to trim the corner to follow the shape of the lid.

Gluing up the lip.

Adding a glass skin

The new hatch lid awaiting hinges and varnish.  See the new sole in foreground awaiting a top coat.