Replaced hatch covers with Starboard - lessons learned

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cudabird

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Model
Fisherman 222
I figured I'd share this with everyone since this appears to be a common problem on older GWs. I bought a used, 2000 Fisherman 222 last Fall. I really love the boat. However, the two rear hatch covers were cracked. I did some research and found a company called www.boatoutfitters.com. (I have no affiliation with them.) I attached a picture of one of the old hatches. I worked with them and did a lot measuring and we came up with a design to recreate them using 1" King Starboard. My original plan was to buy the Starboard and shape it myself but I noticed they do custom CNC designs for a nominal fee. A CNC machine would do heck of better job than I could with my router. The hatch covers close down over a removable box with a lip so some intricate routing would be involved on the underside. The corners and top edges needed to be radiused as well. I chose Seafoam as the color - in hindsight I'd been better off with white but I'll live with it. Anyway, I got them and installed them and I'm pleased with the fit. If I did it again, I might make them 1/32 to 1/16" smaller in case the Starboard expands in the heat but I think I'll be ok. It was ~$350 for both. hatch_2.jpeg49544.jpeg49542.jpeg49546.jpeg
 

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X2 the two tiered cover adds strength and functionality.
 
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I have the same boat and the same issue with the hatch covers. Would you mind sharing the contact info of the person you worked with at Boat Outfitters? Thanks!
 
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GW hatches are junk. I think they use sand from the parking lot mixed with resin as a filler. It's hard and brittle. I made molds for my anchor locker and aft storage box and build new hatches with Coosa board. The aft storage box is topped with Starboard cutting board.

Molds 1.jpeg Plug 1.jpeg
 
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Starboard is an easy way to go and looks great new. I have found that if you use it where people step, it scratches badly and holds dirt.
Also, my fishing buddies will immediately use it to cut bait.

I need to do my anchor hatch and pulpit. I will probably just grind off anything loose or cracked and then glass & fill & fair &paint
 
Does anyone know if the drop in inserts under the hatch are available for 180?

Someone makes them in different sizes?
 
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