Handy way to build hatches/doors with no waste

[Todd j]

I figured this gem out after I reached the cockpit or I would have built every hatch this way.   So simple!!! 
1) Build a pattern oF the door size/shape you want from 1/4” ply
2) set the router up with a pattern cutter and remove the bushing
3) place pattern on whatever panel needs the door using 3M 2 sided tape
4) route out shape being careful not to stray from the edge of the pattern
    The piece that falls from the panel is the door.   I used 10 oz.  tape around    the opening.  And 2 layers of 10 oz.  tape around the edge of the door. 
5) install a flange on the back of the panel.  Don’t forget to add an extra 1/4” if you want a semi water tight anti rattle 3/8” bulb seal

[Brian.Dixon]

Thanks, Todd!  Great tutorial on making hatches with no waste ...   Very nice of you to share!

[Rbob]

Cant wait for the video!   

This will help a lot of people, thanks Todd!

[rhenryinoregon]

That’s very cool! I will use this technique. Are you seeking royalties?

[Todd j]

Ha ha.  Nope.  I’d be flattered if you use this method.  I’m sure I’m not the first one to do this. 

[Lindy]

Todd,
Used your method on my cuddy bunk hatches today and worked great. Cut out hatch template on my CNC, then used router pattern bitt w/o bushing to cut out hatch. Then made a doubler to stop the hatch from falling through on the CNC. Not sure if I will tape the edges as you suggested, or fill thickened epoxy with plastic between the hatch and frame as Randy did on his video, or leave it sloppy since its under the bunk. Thanks for posting the tip, and thanks Randy for the hatch building video.

[Todd j]

I wish I would have wobbled onto it sooner.  Another neat thing about this method is you cAn make perfect fitting replacement hatch if you keep the template, which I plan to do. 
Re: the Randy edge treatment or the way I describe above( adds the thickness of 3 layers of 10 oz. glass) If you make your hatch fit too tight and don’t allow for a minimal gap, depending on the hinges you use, they can bind in the opening and not open or close properly.   They need some “room”