My Hatch Cover Project! Steps/Pics/Details (1 hour, $13!)

jaywoodz

Member
Nov 12, 2012
522
Richmond, Virginia
Boat Info
1999 Sea Ray 310 Sundancer
Engines
Twin 350 MAG MPI Horizon w/V-Drives
I have an original post that I started a while back regarding hatch covers located here. I encourage you to read over that thread prior to continuing so you have an idea of what ideas led up to this project.

Just for a general overview, this post is the process I did for creating very easy to make hatch covers for your Sea Ray (or any boat) in about an hour! These will completely block out sunlight and keep your cabin cool, or if you're like me, I did this so I can sleep in darkness and not get woken up by the early morning sunlight!

Once you've caught up with the post, we're going to start with the step-by-step process on creating hatch covers for $13 & 1 hour!

Step 1: Went to home depot and looked for the every famous "art board" from the last post. Well, when I asked the rep in Home Depot, he looked at me funny. I went out on my own with my friend Mike and found dry-erase board.. yes dry erase board. This is the same material used to write on like in a classroom or work office. It's durable, strong, and THIN! We need thin.. why? because the space between the hatch lever and the screen is 1/8"! Once you find the board, haul it to the boat and double check to make sure it fits! By the way, I paid $13 for this board.

Here is a picture showing the board and its thickness:

image_1.jpeg


Step 2: Okay, we measured the hatch properly by getting a permanent marker and laying the screen down on the board and using the INSIDE where the screen connects to the white part. We drew a line around producing the outline.

Step 3: Double checking TO MAKE SURE we didn't waste any of our time, we decided to cut the corners really quick with a knife and shove it up there to make sure it wasn't too thick and would fit with the screen attached. Here's a pic (background cutting):

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It fits! We then took the board back to our shop and did it the right way so it looks good and doesn't let ANY light in.

Step 4: Grab all your screen and create a template using a permanent marker. Pencil will not work, we tried.

image_3.jpeg


Step 5: Use a standing saw to accurately cut each piece out. I had 1 20x20, and 2 12x12's.

image_4.jpeg


Step 6: Once you're done cutting it, DO NOT FORGET to sand it the corners AND all sides. This is very important to make it fit and ensure there won't be any shavings all over your boat. We sanded it very smoothly and it looked amazing!

image_5.jpeg


Doing the corners.. and the sides.

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Step 7: Blow them off & wipe down with a clean cloth to remove all the shavings.

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Once this is done, you should be ready to rock! Here's a pictuer of the final product 1 hour & $13 later!

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I tried them out in my boat last night (I didn't have my phone with me), and they fit perfectly just like in the 3rd picture I posted except the corners aren't cut off, but rounded. NO light gets through, and they fit perfectly! I store them under my matress and will enjoy them for years to come! I may take a picture with all of them installed and see how much light comes in through the side hatches. Another thing I want to mention, there is a white side and a darker grain side. I recommended putting the white side down so it flows with the rest of the white interior (if you have a white interior).

Hope you guys like, and if you have any questions.. please ask!
 

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How did you secure them? are they easy in /out?
looks interesting RF

Securing them isn't really needed. Once you put the screens back into place, they fit very snug in there and if cut properly won't have any wiggle room to move around. There's only about 1/8" from the handle of my hatch to the screen itself. So actually, it barely fits therefore keeping it in place, nice and tight! They're very easy in and out. Once you remove the 4 swivel tabs to keep the screen in place and the screen drops, the piece of board comes right out on top of the screen when you drop it down. Stored under the mattress, and all done!
 
As stated in the other thread, that's what I did except Ai used a thick art board cut with scissors. You can find it at artist supply stores. Mine is white on both sides as to reflect the heat and still look good on the interior.
 
A craft store probably carries the art board too. You won't find it at a home improvement center but I'm glad your solution worked out too!!


Sent from my iPhone using Tapatalk
 
The art board being mentioned is also known as foamcore, and you can also pick it up at framing shops. Handy stuff.
 
not to be negative to the ingenuity but....
don't those make the screens pretty much useless :huh:
 
Looks great, Nice project. I have a sunbrella cover on my hatch but if I didn't I would be doing this.

LK
 
The art board being mentioned is also known as foamcore, and you can also pick it up at framing shops. Handy stuff.

Not really. foam core is a completely different product from the stiff art board artists use to paint on, and much thinner than Foamcore or another product known as Coreplast.
 
Very nice. Certainly tops my folded up paper towels. From a heat perspective, I wonder how much less strain it will put on the A/C. From a light perspective, I love it. The best sleep I ever had in my life was in my stateroom at sea. Pitch black.

Did you take into account you have (it looks like) in excess of 20 grand in tools in your shop? That makes the real cost about $20,013.00, not including labor!!! :smt043
 
not to be negative to the ingenuity but....
don't those make the screens pretty much useless :huh:

Actually, no. Not at all! You can still remove these and use the screens when you want light to come in! I did this project primarily to keep my boat cool during the summer and keep the sun out of my face when I'm trying to sleep on it. I sleep much better in complete darkness or very little light.
 
Looks great, Nice project. I have a sunbrella cover on my hatch but if I didn't I would be doing this.

LK

After doing some research online, people hate the sunbrella hatch covers since they are a PITA to try and slide over! Not to mention.. you have to unlock the hatch, then go up to the bow and take them off.. or reach through and grab them. All of what I did can be done from inside without any issues or leaving the cabin.
 
Not really. foam core is a completely different product from the stiff art board artists use to paint on, and much thinner than Foamcore or another product known as Coreplast.

This board I'm using is very stiff, won't bend and we did a stress test on one, and I can't bend it enough with a medium amount of force and I'm 29 years old and was a Marine for 9 years. :thumbsup:
 
Very nice. Certainly tops my folded up paper towels. From a heat perspective, I wonder how much less strain it will put on the A/C. From a light perspective, I love it. The best sleep I ever had in my life was in my stateroom at sea. Pitch black.

Did you take into account you have (it looks like) in excess of 20 grand in tools in your shop? That makes the real cost about $20,013.00, not including labor!!! :smt043

haha! Yes I did take that into account, but the best part about it.. NONE OF THAT IS MINE! My roommate (mike) works at a plant and has access to all of those tools and that entire shop 24/7, including weekends! So we can go in there and do what we need to do, no questions asked. Didn't have to pay a single penny!
 
I have started receiving private messages for people that want these made and picked up/delivered! Since it's cheap and doesn't take long to do.. I would imagine I can come up with a price for each size and shipping options! If anyone is interested, email me for a quote: jaywoodz@gmail.com or send me a private message! I live in VA.
 
Actually, no. Not at all! You can still remove these and use the screens when you want light to come in! I did this project primarily to keep my boat cool during the summer and keep the sun out of my face when I'm trying to sleep on it. I sleep much better in complete darkness or very little light.
I was thinking as a boater without A/C I guess
I leave my hatch open at night for some air flow...and the mast lite on top of the windshield is bright as the sun :lol:
 
I was thinking as a boater without A/C I guess
I leave my hatch open at night for some air flow...and the mast lite on top of the windshield is bright as the sun :lol:

Do your side hatches open at all? I can see where this wouldn't work in your favor without running AC or heat.
 
Do your side hatches open at all? I can see where this wouldn't work in your favor without running AC or heat.
no sides...only a single deck hatch and the cabin doors
when I still had the opaque "cutting board" hatch lid I would put a pfd cushion over it at night to block the anchor lite
 
After doing some research online, people hate the sunbrella hatch covers since they are a PITA to try and slide over! Not to mention.. you have to unlock the hatch, then go up to the bow and take them off.. or reach through and grab them. All of what I did can be done from inside without any issues or leaving the cabin.

Huh, I guess I have never taken mine off so I did not know of these issues, I just leave it on to keep the sun off of the interior.

LK
 

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