I wanted a companion way that I could see out of so I copied a mod that I saw a while back when the mod board was up. I cant remember the original person who did it but it was a great idea. Not the easiest to do for me but I think it turned out nice. The wooden rope trim gives it a nautical look and I trimmed my stairs on the ladder with it.
I used silicone to attach the rope trim to the plexi glass and I’m not sure how well it will hold. I think it will be ok but if not I’ll figure something else out. The other trim piece is held with brass bolts. The inside of the hatch is a different size from the outside so the trim pieces don’t match perfectly but close enough. I probably spent close to 100.00 dollars and It took about around 6 hours.
It would have been nice if the boat would have been in the yard instead of at the slip for measuring .
Last edited by MARK PASSMORE on Wed Jun 18, 2008 11:24 pm, edited 1 time in total.
I really like the look and it is a very nice job - especially the trim on the steps - but why so expensive? $100. for plexaglass and trim materials - what am I not seeing - what thickness is the 'glass? - does that include the fan module?
Also can you tell us a little more about the inside vs outside dimension issue.
Yea that does look nice Mark! Good Job! Does the rope on the steps have that similar texture as cocoamat for wiping your feet? Perhaps a small section of 4-6 18" sections of rope in front of the traveller would make a good foot wiper and match the doorway. I made a clear plexiglass doorway myself from an old scratched piece I scrounged, it cost me nothing except my privacy, I like to see out but don't want passersby to see in. I was also exploring the idea of blue tinted plexiglass but that costs more. The boat originally came with smoked plexiglass door but the hot sun warped it so I got a replacement fiberglass one from the dealer. I am also exporing the idea of replacing all my holds with clear plexiglass like I saw posted elsewhere, a bit pricey but I quite like the idea. I have also seen canvas doorways that zip to the dodger on the upper part and snap in place around the doorway and also have a plastic window. They are custom made and cost $$ too! I prefer to scrounge materials when I can or get small pieces I need from the scrap bins at a reduced cost. We have a plastics supply outlet nearby so I will be pricing things out. Now I have some idea as to make it look more aesthetically pleasing!
Thanks guys, The plexi glass is 1/4 inch and I had my niece who owns a window shop cut it. She said the charge would be around $40.00 normally but wouldn’t accept the money from me. I guess she will get reimbursed in sailboat privileges. The trim was 12.00 a stick and it took three 8ft sticks. The flat trim was just pine and it only took one 8ft stick at a few bucks. The brass hardware was around 10.00 bucks I think. Luckily I already had the stain and varnish. I would like to do another one in smoked or tinted glass.
I did have some issues with the inside measurements of the companionway and intended to put the flat trim on the inside but it didn’t fit correctly. I would make a few up and sale them on ebay or somewhere if I can get all the kinks out. I would only do that if I could get the quality higher. Better trim, tinted glass, better fit, and maybe use teak. It’s something Im thinking about doing. We’ll see.
Really nice. That "rope" trim is so cool. I especially like the trim on the stairs. I may have to steal that idea.
I've been wanting to make something similar. My old boat had 2 pieces of tinted lexan for a "day" hatch. It was great when weather drove us down below. The two pieces were cut so that the horizontal meeting joints were angled to let rain water drain down and out like a window ledge. It had no nice frame like your piece of craftsmanship. I'm also impressed you did it sans boat to test your cuts. You must be very accurate at taking measurements.
I really hate that huge companionway hatch Roger gave us. What is the idea of such a bulky piece of glass? I'm thinking maybe it floats.
Tang, If you look close at the inside pic, you can see that the flat piece of trim would have to be cut down because the inside walls are smaller than the outside. If I had just moved the trim over then a person would be able to see the back side of the wood from the outside of the boat. Not pretty. So I just left the flat trim off the inside of the glass. I can still add it later when I have the boat on the trailer. It was at the marina and going back and forth for measurement was a pain.
Mark
Well, in spite of or because of the trips, you still did a very nice job of it. I have been considering replacing that huge white knee knocker with 3 pieces, but after seeing how nice it looks with two and the added benefit of the fan module fitting, I may just copy your work also.
When you stained the rope trim, did you stain the composite ladder steps also? It looks that way.
Tang, I did stain the steps also. I had already done a ladder mod so that I can remove the ladder and posted pics but some pics got deleted from my photo bucket.
Great job ! I just finished a 3/16 inch plastic that fits companion way and a cut out for the 5050 btu air condition, now I need to install the noseeum screen I just got from Starlite. I origanaly was going to make up two 1/2 inch aluminum panels for companonway but there is to big a gap around the slideing hatch for the no-seeums to get thru so I will use Velcro in 2 pieces.
I don't like useing the AC except on shore power and it gets hot and muggy here in SW. FL. July 16th will do a 5 day cruise with the WCTSS in the keys (South Dade Marina) and see how good my 3 fans aboard work.
I could just get 2- 12 inch jet fans and put in bow berth but that use a lot of elect.
By the way, South Dade Marina charges $5 a day for launch and storage, cheapest in the Keys for you folks doing a Keys trip. http://southdademarina.com/
Dave
You mentioned you had some smoked plexiglass and it warpped.
Any idea what is a good product or thickness to work with.
I want to add a hatch like others have and I can see a lot of detail goes into getting it to fit right.
Mark,
Excellent job, I am jealous !!!!
Guessing I will end up needing 2 configurations, one for A/C one for normal usage and the original stored at home for a spare, HMMMM, lots of doors i guess !!!!!
Update. The rope trim did not stick to the glass very well with silicone. So I had to remove it and scrape off the silicone then reapply it with Gorilla glue. I Hope it holds up better. I ended up putting a few scratches on the glass. Man that stuff scuffs very easy. I think I’m going to try and window tint it very dark and maybe it will help cover up some of the scuffs.
So I just left the flat trim off the inside of the glass. I can still add it later when I have the boat on the trailer. It was at the marina and going back and forth for measurement was a pain. 
