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TOPIC: My 32XX Cave Hatch Project

My 32XX Cave Hatch Project 23 Mar 2014 11:33 #1

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There have been many posts on this project so I thought I add mine to the mix. First off, many thanks to the contributors of this thread:

www.baylinerownersclub.org/index.php/for...2xx-cave-hatch-again

This was very helpful in planning my project which was inspired by my need to replace the raw water intake hose for the head and holding tank. After banging my head and scrapping my back a few times crawling in and out of the cave I thought "enough is enough...I'm cutting that hole".

Here is my progress so far....

My opening is 24" x 42" and is 8" from the helm. I wanted it as far forward as I could get it.






I then made my straight cuts on all four sides with a circular saw using a narrow kerf blade (Freud 40 tooth for finishing and plywood) and it cut beautifully. I had a friend follow me with a shop vac to catch some of the dust but lets just say I have A LOT of vacuuming to do.



Before I cut the curved corners I positioned and traced the SS table hinges I'm going to use as it needed to be routered. I was easier to do this now. I only had about 3" from the hinge center (closest to the helm) to the cabinet to fit the router. I just had enough room.







Next, I went below the hatch opening and screwed in two lengths of strapping to support the hatch cover while I cut the corners. This prevented me and the hatch from falling through the hole.

I used a 10 TPI down cutting jig saw blade for the corners. My jig saw has a scrolling feature which I need to use to get around the corner closest to the cabinet. The fiber glass was extremely hard on these blades and I burned through 4 making these cuts.





The flange I'll be using is a half sheet of 3/4" plywood. I left a 3" mounting surface all around the flange and a 1" lip for the hatch to rest on. The over all flange dimensions is 30" x 48". My friend took the hatch we just cut and positioned it on the plywood and traced it. Then measured in 1" from the traced line. Easy.

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"Martini's Law"
1986 Bayliner 3270, 110 Hino's
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My 32XX Cave Hatch Project 23 Mar 2014 11:39 #2

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Here is the flange almost ready for install. I will be pre-drilling the holes in the flange for the SS screws. I originally bought #10 1 1/2" but determined they were too long so I be using 1 1/4".





So this is my progress so far. I hope to get back out today to finish up.

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My 32XX Cave Hatch Project 23 Mar 2014 11:51 #3

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diveguy wrote: Here is the flange almost ready for install. I will be pre-drilling the holes in the flange for the SS screws. I originally bought #10 1 1/2" but determined they were too long so I be using 1 1/4".





So this is my progress so far. I hope to get back out today to finish up.


So how will you get the flange down the hole? Seems like you ned to cut it into 2.
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1997 Maxum 2400 SCR 5.7LX Bravo II

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My 32XX Cave Hatch Project 23 Mar 2014 12:00 #4

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[/quote]So how will you get the flange down the hole? Seems like you ned to cut it into 2.[/quote]

HA! That is an excellent question and you gave me a moment of panic there. I should be able to bring it through the cave entrance from the aft berth. But if not then yes, I'll have to cut it in two.

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My 32XX Cave Hatch Project 23 Mar 2014 12:06 #5

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diveguy wrote:

So how will you get the flange down the hole? Seems like you ned to cut it into 2.[/quote]

HA! That is an excellent question and you gave me a moment of panic there. I should be able to bring it through the cave entrance from the aft berth. But if not then yes, I'll have to cut it in two.[/quote]

Got it. Wasn't sure if you had a trick that isn't appearant from the pictures. Keep us posted on the progress.

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Mike

My 32XX Cave Hatch Project 23 Mar 2014 17:27 #6

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Well it's finished and I'm glad I did it.

I couldn't get #10 1 1/4" screws so I got #8's instead. I was a little worried they wouldn't be big enough but they were fine. I have at least 75 screws plus 5200 adhesive holding the flange in place.







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My 32XX Cave Hatch Project 23 Mar 2014 17:30 #7

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Geat job!

Did you seal the wood with anything? Resin. Hate to see it rot down the road.

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My 32XX Cave Hatch Project 23 Mar 2014 17:36 #8

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Nauti Mike wrote: Geat job!

Did you seal the wood with anything? Resin. Hate to see it rot down the road.


No I didn't actually. I'll seal it eventually but I'm not too concerned about it given it's in a area that is dry.

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My 32XX Cave Hatch Project 23 Mar 2014 18:18 #9

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Looks great, good job Trevor!!
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Nick
1988 3218 "Selkie Song"

My 32XX Cave Hatch Project 24 Mar 2014 01:12 #10

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nickatnite wrote: Looks great, good job Trevor!!


Thanks. Next task is to replace to raw water hose for the toilet. I think I'll be cutting some access holes in the vanity to route the new hose as others have done.

And thanks for sending me your pictures as well.
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My 32XX Cave Hatch Project 14 Apr 2014 00:28 #11

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"]No I didn't actually. I'll seal it eventually but I'm not too concerned about it given it's in a area that is dry"


Not to belabor the idea, but dry or not, the plywood will become distorted and begin to decay with just air. SEAL it FAST! B)
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My 32XX Cave Hatch Project 14 Apr 2014 17:45 #12

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Thanks David. This is on my "do to" list before launching. This was an oversight in my urgency to get it completed as I would have coated it with resin prior to install.

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My 32XX Cave Hatch Project 22 Apr 2014 02:00 #13

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Great job and thanks for the very helpful pictures!

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CapMartin, Montréal
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My 32XX Cave Hatch Project 23 Apr 2014 22:34 #14

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CapMartin wrote: Great job and thanks for the very helpful pictures!


No problem. This was a great mod for me as I had to run new sanitation and water lines and install a holding tank and macerator. It would have been a real pain to have to go through the aft stater room.

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My 32XX Cave Hatch Project 22 Apr 2015 17:01 #15

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Dave, I am getting ready to do this myself next week! Can you tell me what adhesive you used to bond the flange to the bottom of the deck? I see that you used screws from beneath so I hope that adhesive is really strong and reliable as my chair will be directly on top of the hatch and I'm 6'4" and 260 lbs. I was considering counter sinking bolts from above and have nuts and washers on the bottom as an alternative. It would be a little messier on top but might be more secure. Not sure. The carpet will cover it either way. Thanks again for sharing this with all of us.

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My 32XX Cave Hatch Project 22 Apr 2015 18:03 #16

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3M 5200 as stated in #6. Using this with screws underneath and you should have no problem.

Trevor

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My 32XX Cave Hatch Project 12 May 2015 01:31 #17

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I have finally cut it open!
I used a jiggsaw and almost completely controled the dust by keeping the vac at one inch from the blade at all time.
One person concentrating on the cut while an other one handles the vac.
Here is the 24"x40" hole right after removing the heater:




I constructed the flange out of 3/4" oak boards that were glued with 5200 and screwed with 1 1/4" #8.

Final result:




Thanks everyone. Without the infos available here I doubt that I would have done it

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My 32XX Cave Hatch Project 12 May 2015 01:48 #18

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Nice job to both of you. I also want to do this but cant take anymore of this pre boating madness and will attempt it in the fall after I get pulled out.
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My 32XX Cave Hatch Project 12 May 2015 02:06 #19

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Wow what a huge difference. Nice job. This'll be me next year
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My 32XX Cave Hatch Project 26 Mar 2016 14:44 #20

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Hi Trevor, I am going to try to cut the opening for the hatch this spring.How far from the side did you measure to make the cut for the opening.
As you know I definatley need it.Not much room inside to service hotwater tank and pumps as you have seen.
Also where did you get the blades?
My starboard side fuel tank leaked, contemplating cutting it out and using area as storage or replacing with plastic tanks. Filled it with bilge cleaner and water then pumped it out and added more bilge cleaner and a bit more water til I decide what to do.Running both motors off of the 1 tank.Not sure if i have to remove the motor or just remove the risers to remove and replace tank. May have a bit more room as I have 305's.
One good thing about it is it fixed the starbord side list that is common in the 3270.

Kevin
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My 32XX Cave Hatch Project 26 Mar 2016 16:40 #21

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Hi Kevin,

I was about 3" from the side. I just had enough room to make the corner cut so keep that in mind.
I bought the circular and down cutting jig saw blades at Rona in tantallon.
Too bad about the fuel tank. I know I have to face this at some point. let us know how you make out with it.
PM me if you need a hand with the hatch.

Good luck.

Now that I look at those pictures I think it was more like 5". It was when I routered the hinges that the cut was about 3".

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My 32XX Cave Hatch Project 31 Mar 2016 15:40 #22

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That's so helpful thank you very much :)

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My 32XX Cave Hatch Project 31 Mar 2016 16:42 #23

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I cut my hatch in last fall before pull out and still open it every now and then for no real reason and just go Whoa!!!! :cheer:

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Dan
Frostbite Falls, Minnesota
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My 32XX Cave Hatch Project 31 Mar 2016 17:09 #24

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floatyerboat wrote: I cut my hatch in last fall before pull out and still open it every now and then for no real reason and just go Whoa!!!! :cheer:


+1

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My 32XX Cave Hatch Project 07 Apr 2016 21:57 #25

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floatyerboat wrote: I cut my hatch in last fall before pull out and still open it every now and then for no real reason and just go Whoa!!!! :cheer:


You ain't right. :silly: :blink: B)

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