lost hatch door need to make new one

I lost the hatch door (i guess you call it that?) for my wilderness systems tarpon late 90's model. Right now I have a janky plywood door over it but water gets in. Water actually gets in the front door as well (bad design). Anyways I need to construct another door for it and I am looking for any advice. The doors are no longer make so I must construct one. I thought of wooden or maybe making a fiberglass door. The good thing is the other existing door is the exact same dimensions so I have a model to use. Not sure how to make a mold though? ANy help i s appreciated. WOuld even pay someone to do it for me who knows this stuff.

Making a fiberglass mold can be done with time and $ but is probably more than needed. I am not sure of the lip design and size so I have little more advice. It may be possible just to make a cover for the hatch such as a spray skirt if it can be made to shed water rather than gather it. Maybe the skirt over the plywood? Just throwing out some ideas.

They dont sell hatches for it anymore I take it?  How about a neoprene seal stretched over the opening and secured by bungies or something?

Having lost the hatch to my 05 tarpon this has been on my mind. Seems to me the best thing would be to sew up a neoprene hatch cover with a bungee rand, then make up a fiberglass hard shell to go over it. Secure the hard shell with bungees or straps.

This is how all hatches used to be....

Pics can you cut it bigger and put a differant hatch in?

http://topkayaker.net/TopKayakerShop/index.php?main_page=index&cPath=2_18_96&zenid=k319j8icqkvpthjcumto31f5k4

The problem with that Dual Hatch Tarpon kayak is there is no overhanging lip on the opening to secure anything to. The original cover is hard plastic with a rubber seal on the bottom. It seals by using downward pressure from 3 straps over it. I've wondered what I would do if I break or loose one of mine like that. There really isn't an easy solution that I know of. One of ine has a small crack that I need to fiberglass or epoxy.

Here are some pics of what it looks like. I also found an older tankwell insert that is good for lake fishing, but I'm sure will fill with water in the ocean.


I'm pretty sure this is the kayak he is talking about.

    For a one time mold,   I'd suggest taking a piece of styrofoam ,   shape it to the desired dimension / configuration .     Then using epoxy, lay up  FG or Carbon Fiber...     if you are using straps to hold it down.   There is some moldable silicone available through Aero Marine in San Diego area that you may be able to use as a seal.

    My Wilderness Tarpon had that heavy rubber hatch lid.  It seemed to pop off easily while being transported on the car.   

      Make it  bomb-proof.

My newer Tarpon hatch stays on just fine. Nice and tight.

    My Wilderness Tarpon had that heavy rubber hatch lid.  It seemed to pop off easily while being transported on the car.   

Yeah, I've learned this the hard way. My original hatch is now part of the decor on Hwy 101, somewhere around Gonzalez...

I found a decent deal at Austin Canoe & Kayak, if anyone needs rubber tarpon hatches.
I'm putting straps across the new one. 

Thanks for the pics RacinRob, they do a great job of illustrating the issue with adapting a different hatch style to that older boat.
Still, these hatches aren't highly machined with moving parts or anything, so I would think that building a one-off should be possible. I almost wonder if a sheet of plastic, a wooden form, and a heat gun would work to form the lid, and then you could just glue the rubber seal onto it.....

Is it a dual hatch?
If you have one existing hatch cover just use it as a mold for making a fiberglass copy.
Decide which side of the hatch to mold, copying the inside will make a smooth topside,copying outside will make a smooth inside.
Remove the seal and clean it up and spray mold release on it and lay-up some glass. You could use epoxy instead of polyester resin if you are worried about heat warping the plastic.

    My Wilderness Tarpon had that heavy rubber hatch lid.  It seemed to pop off easily while being transported on the car.   

Yeah, I've learned this the hard way. My original hatch is now part of the decor on Hwy 101, somewhere around Gonzalez...

Same here!  Just as I took home Sara's boat, damned thing flew off.  Was wondering if you guys had your yaks right side up or upside down?  Mine was down, and I think that had something to do with it.  It's re-enforced with a tighter strap and hasn't come off since. 

     Mine was down , forward.      That hatch started beating against the windshield at 55 mph. 
Shocked the p^*$$ out of me.

 Since then,  I've always strapped it  stern forward , have never had it happen again.   Fortunately it did have a safety line attached.   Wonder how many have ended up on  roadsides  next to  hubcaps

Remove the seal and clean it up and spray mold release on it and lay-up some glass. You could use epoxy instead of polyester resin if you are worried about heat warping the plastic.

This...^^....is money. 


I'm neck deep in fiberglass work on my boat right now, waiting on materials but I got a hatch and will try and get one layed up when I start the glass on my boat.