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Construction of a sliding companionway hatch for a 52-foot sailboat involves laminating a composite panel using PET foam, cedar perimeter framing, and biaxial fiberglass.3:54 Because the original deckhouse cutout proved skewed, the build requires a custom-fabricated hatch designed for structural rigidity and insulation.3:32 The lamination process utilizes vacuum bagging to ensure consistent bonding, with the crew applying 600g biaxial glass to both sides of the foam core.7:24 To manage cold ambient temperatures—dropping to 5–10 degrees Celsius—the process incorporates fast-acting epoxy hardener, infrared heaters, and heat blankets to maintain proper resin viscosity and saturation.17:19 Future steps include installing sliding tracks, integrating a drainage system for the hatch garage, and developing a cam-action seal mechanism to ensure the hatch remains watertight when closed or partially open.19:58 The final design prioritizes strength, allowing the hatch to support a person’s weight while positioned under the boom.19:03

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