A few months back, I installed a defective solar powered vent on the forward hatch. It turned out to be one of those lessons that will not be repeated :-)

I found two of these vents for quite cheap. First mistake was buying two of them. I needed to rebed the glass in both hatches as they had begun to leak.  It seemed that putting a solar vent in each one was a good idea. Only 5200 was available. Kind of a permanent sealant for what I was doing. I just figured that as long as I was careful....All would be well. My work was good. vent was not only defective, but now everything was put together with 5200.

I sealed it up with aluminum tape. When I got the time I would fix it.

  This time it would be done correctly. I thought about it. I decided installing something that would potentially leak, right above the v-berth, was not acceptable. This meant new glass. I got online and ordered polycarbonate glass. I got enough for 3 hatches. It was cheaper to order that amount.

I have been busy, so it took a while to get around to the hatch. I also was dreading the 5200 I had bedded the glass with last time. I tried cutting it out, around the edges, with a razor knife. Not so good. Keeping in mind the rubber seal below the glass. I needed to save it. I had no idea where to get another. At least on short notice.

I gave it some thought. When it does not work by hand....incorporate a power tool. I put a Dremel cutting disc in the drill. Did not work. I decided to try a cutting drill bit made for Dremel. Bullseye. It walked down the frame, pulling the sealant off the aluminum cleanly. Well...It roughed up the aluminum a little, but all that would be hidden by sealant. It was time consuming, but I got it done

Now it was time to cut out new glass. It needed to be perfect. Fortunately, I just happen to own a good bandsaw. A big bandsaw.

It made the cutting easy.

Perfect fit in the frame. I forgot to take a picture of the drill press. Holes for the handles and hinges needed to fit perfectly. I clamped the old piece on top of the new one. Put proper bits in drill press and drilled holes.

You can see them here with baling wire run through them for handles. When bedding new glass. You have to use a bead of slow cure on top of rubber seal. Set glass in with as little movement as possible. Then let it cure before doing the edge with fast cure. The clear glass made it difficult to see the edges. I put the pieces of tape on just so I could clearly see the edges. It worked great.

Finally got to seal the edges.

I put white privacy tint on it and installed hinges and handles. Everything fit beautifully. Off I went to the marina to install it.

I sat in the van watching a storm roll in. I had tapped the opening. I could only hope it held up. It poured mercilessly for over 30 minutes. The picture does not do it justice. An hour after this picture, I installed the hatch in full sunshine.

I have sun shade fabric coming in any day. I will be doing the screen for shading boat any day now. I hope it turns out as good as the hatch.