[C320-list] Replacement teak hatch boards

[Dean Vermeire]

I have to agree with Tony, in that the Zarcor doors are really not the 
best for securing your boat and keeping the bad weather out while you 
are away.  I bought the Zarcor doors for our boat (#847) to easily go in 
and out of the boat in the summer, while keeping the cold air from the 
air conditioner inside.  We only use the doors when we are staying on 
the boat.  Otherwise, we put the hatch boards back in.

The installation was pretty easy on my second attempt.  The instructions 
all make perfect sense when you are done.  There are a couple of little 
tricks that would be great to know up front. First of all, clamping both 
doors securely to the included flat piece of plastic (or, better yet, a 
piece of plywood or straight board) helps tremendously.  Second, using 
thin strips of plywood or hardboard as shims is a big help.  The idea is 
that the doors are clamped together and act as one piece to install.  
The shims are placed behind the doors in the slot, on the outsides of 
the doors in the slot, and under the doors.  This provides some space 
around the doors and pushes the doors outward, so that the hinges will 
be properly positioned.

Before drilling any holes, and after you have clamped and shimmed, slide 
the hatchway cover closed and check the clearance with the doors.  If 
you can't close the hatch cover, or if it rubs, you will need to take a 
little off the bottom of the doors to lower them down.  I did not need 
to do this at all on my boat, but each boat may vary slightly.  Once you 
have the doors (still clamped and shimmed) fitting nicely, you will want 
to press the hinges firmly against the doors, pulling the doors towards 
the hinges, and drill the holes.  It is very important to drill and set 
the screws with the hinges aligned properly.  Once you have the hinges 
set, just remove the clamps and shims.  Ta da!

As to the various comments about the hatch boards, I took mine home with 
me to refinish them this weekend and have a few observations.  First 
off, the quality of the hatch boards is first rate, at least on hull 
847.  They are solid wood (probably teak, although possibly one of the 
good substitutes).  The main panels are edge glued and there are end 
pieces that are glued cross-grain with mortise and stub tenon joinery, 
similar to breadboard ends on a dining room table.  Because the joinery 
is cross-grain, it may fail over time.  This is not because it is a bad 
design.  The nice, finished look is achieved by the breadboard ends that 
hide the end grain of the main panels.  The down side is that the joint 
may break apart over time, due to seasonal movement.  If this happens, I 
would rebuild the existing hatch boards, salvaging as much as I can.  
Certainly, the main panels would be salvageable. The end pieces may need 
to be replaced.  It depends on how easily you can get them apart and 
clean out the old glue.

If you decide to build new hatch boards, there are some alternatives to 
teak.  Genuine teak is selling here for about $24 / bf.  However, Iroko, 
which is a very good substitute, is selling for about 1/3 of that.  
Mahogany would also be nice, and African Mahogany is a good substitute 
for that.

Good luck.

Dean Vermeire
Moonstruck II (#847)

On 9/28/2012 9:29 AM, Tony Murphy wrote:
> Len,
>
> We have the Zocor doors (installed earlier this summer).  As we spend many
> weekends on the boat, we absolutely love them and highly recommend them for
> people who are going in an out of the cabin a lot and hate wrestling with
> the hatchboards.  However, when sailing, these are removed and placed in the
> aft cabin.
>
> For a day sailor, I don¹t think I could recommend them.  They aren¹t as
> secure when away from the boat as the original hatchboards, but then again,
> if someone wants to get in your boat, they¹ll get in.
>
> Installation is easy to moderate, but not quite as easy as they make it out
> before the sale.  I had to some sanding on one of my doors at the bottom
> with an orbit sander (about 10-15 mins).
>
> So, if you¹re only purchasing them to keep the rain out while you¹re away,
> then they seem like an expensive option.
>
> Tony Murphy
> Bella Sol #886
> Leech Lake, MN
>
>
>
> On 9/27/12 11:22 AM, "Len" <aqua5len at gmail.com> wrote:
>
>> Thanks - my wife and I are strictly day sailors out of MDR up the coast for
>> a few hours, then back to the Club, and only in fair weather - have no need
>> for boards IF doors keep rain out of cabin when shut.
>>
>> Are there other brands to consider before I buy from Zocor?
>>
>> Len
>> AQUA5 #1070
>>
>> On Wed, Sep 26, 2012 at 9:10 PM, <JCowperthw at aol.com> wrote:
>>
>>>> I had .375 tinted polycarbonate sheets cut to size. They are great  when
>>>> dodger is up but switch back to factory in the winter, as they allow some
>>>> water in without it up. Reasonable privacy and allows a lot  light.
>>>>
>
>
>