This one is not for the faint of heart!
Significant deck surgery, involving cutting
and fiberglass work required.
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Correcting a genetic disorder!
My main camping and cruising sea kayak, the ‘Banana Boat‘ is a 1992 model Seda Glider which originally came equipped with only a very small VCP style 8″ access hatch for the entire front compartment. This severely limited the kinds of items I could carry in the otherwise large space provided. My first step to improve access was the addition of another hatch into the front bulkhead itself, as previously described in:
Accessing the space within – adding a front bulkhead hatch!
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While this worked pretty well for carrying long items such as chairs and tripods, in practice it was a chore shoving drybags in and out through the cockpit. Loading this way also proved nearly impossible from any significantly elevated platform. In the end, the only real solution was to cut out the tiny round hatch and fiberglass in a much larger oval hatch opening.
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Why the need to carry so much stuff? Well, for me a big part of kayak touring and voyaging is my photography, so I probably end up with about twice the amount of gear of a typical touring paddler. I like to be a able to carry a 3 foot tripod or long lens. It’s also really nice to be able to take along a regular-sized folding chair – in addition! 🙂
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Read on at your own risk!
For the new replacement hatch, I chose a much larger 11×18 inch oval hatch from SeaDog, similar to these Sea-Lect hatches available from here. It completely dwarfs the original tiny 8″ opening! The rim is injection molded plastic and the lid strong but lightweight. The new setup actually weighs a bit less than the old solid rubber Gaspachi hatch lid pictured above, so I incurred no weight penalty!
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On the Glider, I determined that the best way to proceed was to leave the cockpit-side of the original rim in place, and only cut out forward. The sectioned and contoured part of the cut out was then reused and epoxied in place to form opposite ends of the new oval opening. After this cured, it was only a matter of filling in along the sides to complete the oval opening and join it to the deck. I used strips cut from styrofoam plates to add stiffness to the fiberglassed sides. A poor man’s take on foam-core sandwich construction! This method also made it relatively easy to keep the oval level and even. This was important so that the new plastic rim would epoxy properly to the deck!
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Before and after!
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Although I spared you the grisly details of the operation itself, let’s just say it wasn’t pretty. I used a dremel disk to cut away the old plastic rim and a hand saw for the fiberglass to keep the dust levels down. Fiberglass work is relatively easy, but it is a messy job!
The end result looks pretty good I think. When snapped shut, the lid sits recessed below the deck height, just like the original small hatch. If I ever find matching yellow paint, I might even sand it down a bit more. As it is, it has also proven plenty strong over the years!
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I have to say that this is the best thing that’s
ever happened to the Banana Boat! 🙂
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Enjoy!
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With that said..
Blessings friends!
🙂