The flange for the lexan is about 1/2" to 9/16" deep. The Lexan
was 3/8 thick. This means there is a rim that will always hold water.
I thickened the flange up to get the top of the Lexan just above the rim
for drainage. I chiseled the gel coat from the flange surface and
prepped it for epoxy. I cut some 0,90 biax glass (w/mat backing)
in stips and epoxied four layers in place. I used the plexi with
some plyethelene sheet taped to it to press the fiberglass while
it set. I ended up with a smooth surface that made the flange about
1/8" thicker and a lot stronger. I ground down the rough surface
on the inner edge and prepped the new glass surface for more epoxy.
Using some sheet plastic that products come in (e.g. blister packs
for batteries) I made a coffer around the inner edge. I weighted
the middle of the hatch so it bowed down a bit. Then I poured in
epoxy thickened a bit with 406 filler and let gravity level it out.
When it was cured I removed the weights and the coffer and sanded off the
meniscus lip. I sanded the surface a bit to fine tune the height.
The lexan sits on it with an upward bow in the middle of about 2mm
for better drainage. The top of the Lexan is a bit less than 1mm
above the flange on the hatch. It will be a little higher with sealant.
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