Deck Hatch Installation & Portlight Replacement | Custom Composites & 3D Printing

This video documents two key upgrades in the Paikea refit: the professional installation of custom deck hatches and the complete replacement of leaky portlights on our Catana 42 catamaran. In the first half, see the process of fitting and aligning a new composite deck hatch, focusing on the use of 3D-printed jigs for perfect hinge placement. The second half covers the engineering behind converting failed, inward-opening portlights into outward-opening hatches with integrated gutter drainage. The focus is on professional methodology, from solving deck curvature challenges to implementing permanent, watertight solutions. CHAPTERS: 0:00 Introduction: Fitting Composite Hatch Rim 1:00 Deck Hatch: Cutting the Deck & Fitting the Frame 4:10 Using 3D-Printed Jigs for Precision Hinge Alignment 6:45 Drilling Hinge Holes with Custom Fixtures 11:30 Portlight Replacement: Removing Old Units & Cutting New Openings 13:00 The New Hatch Design: Integrated Gutter & Drainage 16:45 Final Installation of Side Hatches 19:30 Detailing: 3D-Printed Drain Fittings SAFETY DISCLAIMER: PROFESSIONAL WORK This video documents professional marine work with significant risk of injury or vessel damage. This is NOT DIY instruction. You are solely responsible for your own safety and actions. We are not liable for any application of this information. Full Disclaimer: https://youngbarnacles.com/website-disclaimer/ USEFUL LINKS ➜ Supporting blog post https://youngbarnacles.com/professional-boat-hatch-installation/ ➜ Want to go deeper? Access our detailed composites videos, project files, and community on the Youngbarnacles Members Hub: https://youngbarnacles.com/plans/all-access-memberships/ ➜ Need world-class engineering for your project? Learn more about our professional design and consultancy services at SYAS Performance: https://syasperformance.weebly.com/ ➜ Free Sailing Library: Check out our free guides on composites, systems, and seamanship: https://www.youngbarnacles.com/resources MUSIC YouTube Audio Library ➜ https://www.youtube.com/