Filling a Forward Deck Hatch | Structural Patch on Paikea

This episode documents the removal of a leaking forward deck hatch aboard Paikea and the process of filling and structurally rebuilding the opening. The hatch over Harry’s bunk had been a long-term source of water ingress. Rather than replacing it like-for-like, we decided to remove the opening entirely and move ventilation to a side port light positioned under the gunwale, where it’s protected from direct rain and green water. The video covers: Why this hatch was removed rather than replaced Cutting and filling the deck opening Foam fitting in a cambered deck Hand laminating versus infusion trade-offs Laminate thickness, resin choice, and consolidation Why closing the opening significantly stiffens the deck panel This isn’t presented as a universal solution. It’s a record of one specific structural decision on Paikea, made within the constraints of time, access, and how the boat is actually used offshore. CHAPTERS: 00:00 Cutting another hole in the boat – why this hatch matters 01:00 Why the forward hatch keeps leaking 01:02 Decision: filling the hatch instead of replacing it 4:54 Two hatches in – preparing to fill Harry’s hatch 7:14 Shaping foam to match deck camber 09:01 Cold conditions and curing the foam 11:38 Hand laminating vs infusion (and time pressure) 15:27 Can you walk on it yet? (skin structure explained) 19:49 Overhead work and inside skin plans 01:20:00 Why the outside wasn’t infused 21:00 3D infusion explained (and why it wasn’t done here) 24:20 Infusion pleats explained – avoiding resin ridges 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/ ➜ 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/