So, the new hatch arrived from the UK, hand-delivered by my brother David, complaining slightly as it was large and heavy.
Fitting the New Lewmar Ocean Hatch
In our construction practice, we often verify the squareness of openings by using a simple method of attaching a string line across the diagonals in an 'X.' If the two strings meet at the center, it's a sign of precision; if there's a gap, it's a call for corrective action. Lewmar's tolerance of +/- 1mm overall flatness so that is what we did.
We then needed to match the frame corner radius (approx 100mm) to that of the hatch frame (74mm). Firstly, the frame was stripped to bare metal. We then offered up the new hatch and traced the required radius. A cheap Chinese trim router and carbide-tipped bit gently removed aluminum until the new hatch frame had the correct radius and fitted without forcing it. Seeing the damage disappearing is therapeutic. Then, clean up the mess of sharp metal bits and dress all the edges.
We then drilled fixings in 2 corners, tapped, and temporarily fixed the hatch rim with Helicoil before adding the remaining holes and Helicoil. The deck covering of "Theadmaster" was cut back appropriately, and the remaining surface was taken to bare metal. Once set, the hatch edge was defined with painter's tape to keep sealant off the Treadmaster. Sikaflex sealant is like molybdenum or "creepy grease." Darn, stuff gets everywhere and is a pig to remove. We left the Sikaflex until the next day, removed the painter's tape, and cleaned any overspill with a pan scrubber.
Spot the anomaly? The hinge is backward, done on purpose, as the support underneath at this location is much stronger than the aft side, so there is something for the hinge screws to bit into. Then came the crucial testing phase, and out came the hose again! The result? Tight as a Cardinal's purse strings. Job done.
Final Thoughts
A tight initial specification would have avoided this problem; do not leave this to chance; decide before the final price is set. That way, untested suppliers or yard-created "masterpieces" can be avoided, and you can put them to sea with peace of mind. I understand that everyone makes mistakes, though the measure of a man or a company is how they handle them. Naval Yachts did correspond, but that is all they did.
What is coming up?
We had a visit this week from Harnell Marine Electrical, a specialist marine electrical firm based in Hamble, Hampshire, UK. They came out to review our electrical installation with a fresh pair of eyes and different training. The good news is that it is well-installed with good support and separation between AC, DC, and Data cables. However, we still generated a snagging list and started chewing through it!
We also met with Dahlberg SA Marine Electronics of Palma de Mallorca. They came to calibrate our Furuno instruments (SOG/STW, Depth, and Autopilot). No disrespect to Turkish suppliers, but speaking the same language was helpful. Multiple duplicated systems now give the same reading, and our relocated Furuno Autopilot is also calibrated. Perhaps the difference between a good voyage and an insurance claim!
Lastly, thanks to the local Victron and MG Systems supplier akuPalma. David O'Neil and his wife, Magda, were super helpful in improving our solar performance and identifying a single point of failure on the 1000amp MG Systems DC bus bars (with an easily implemented solution!)
More on that in a later Blog.
Chris Leigh-Jones
Boat cleaning duty this weekend, my family is joining us in Palma for ten days, Sebrina's interior standards and not mine, and I've been sleeping on the flybridge for the last four weeks .... cushions - yikes!
