Aft Cabin Sliding Hatch Rebuild
The aft cabin on Queen of Hearts has a sliding teak-framed hatch over the companionway. It started leaking. The original polycarbonate panel had cracked near the corners and the sealant had worn away. Rather than reseal around the old plastic, the whole hatch came apart: new polycarbonate panel, fresh 4200, cleaned-up teak.
What Was Found
With the hatch pulled off the boat, the scope of the work was clear. Years of grime had accumulated in the stainless track and around the frame. The underside of the panel showed the problem: the polycarbonate had cracked near the corners and the sealant had worn away, giving water a path in. The teak itself cleaned up well.
The opening with the hatch out. The stainless track and surrounding area had a lot of built-up grime.
The underside of the original panel. Cracks near the corners and worn-away sealant were letting water in.
New Polycarbonate Panel
The original panel was cracked and needed replacing. A 3/8" polycarbonate sheet was cut to size as a replacement. The original had been frosted rather than clear, so the new panel was sanded on both faces to diffuse light and eliminate the see-through effect.
Testing the sanded finish. The right side has been sanded; the left is still clear.
Reassembly
With the teak cleaned up and the new panel cut, everything was dry-fit first to confirm fit and screw alignment before any sealant went in.
New panel dry-fitted in the frame. Everything confirmed before sealant went on.
The panel was then masked with blue tape around the full perimeter and bedded with 4200. Screws were run through the teak frame to clamp the panel down, and the tape came off after the 4200 cured.
Masked for 4200.
4200 applied, screws in, curing.
Tape off. Ready to go back on the boat.
The hatch slides cleanly, the teak looks good, and no water gets through.