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HATCH INSTALLATION INSTRUCTION Tools Needed: Jig saw, drill, 3/16 drill bit (for rivets & well-nuts), rivet gun and/or screwdriver, tube of 100% silicone sealant (clear), magic marker. Also helpful are: putty knife, paper towels, sharp knife and ruler. Other parts required: 12 Rivets or stainless steel nuts and bolts (length will vary depending on hull thickness, but 5/8" seems to work on most boats. INSTRUCTION: For comfort's sake, place boat at waist height (saw horses, pickup bed, etc.), gather all tools needed, and read/understand instructions completely. 1. Identify a suitable place to install hatch. Use rim (upside down works best) to find a flat place large enough and flat enough to accept full diameter of hatch with a little room to spare, and avoiding low areas such as tank wells. 2. Flip lid upside down to use as a template for marking the hole, and draw a circle using the outer edge of the lid as a guide with a fine point marker. Now's a good time to double check all measurements! 3. Use drill to make a hole inside the circle you have drawn. This will allow you to insert the jig saw blade. 4. Use jig saw to cut out the opening for the hatch. Cut just inside of the circle you have drawn, just barely leaving the marker's line. Check the fit with the Rim by inserting it into the opening. Trim opening with a sharp knife or the jig saw if it's too snug, and go with a healthy amount of silicone in the next step if it seems too loose. 5. Apply a thick bead of 100% pure silicone sealant all the way around the flange of the hatch rim. Apply enough silicone so that when the rim is secured a small amount will squeeze out all the way around. Keep in mind that you must work quickly, as the silicone will harden after only a few minutes. 6. Insert Hatch Rim into opening, ensuring a nice even seat. Using drill with 3/16 drill bit, drill your first hole using a screw hole in the rim as your guide. Apply a bit of silicone to your fastener, and tighten snugly. Drill your next hole in the opposite hole on the rim, seal fastener with silicone and tighten. Some silicone should squeeze out from under the head of your rivet, screw or bolt, which should be wiped off quickly. Continue drilling, sealing and fastening in the order of opposite holes, just like tightening lug nuts on a car wheel. 7. Keep your work area clean, with a fresh paper towel supply on hand for wiping up excess silicone. If areas remain and have hardened, simply rub off, or peel/scrape the thicker areas. The silicone will harden into a complete gasket, so use caution NOT to remove silicone under the hatch rim, as this may result in a leaky boat. When in doubt, leave it there (that's why clear silicone is the best choice!) 8. After the silicone has been cleaned and is hard, screw on your lid and go paddle! |