How to build a flush deck lid.

[Evan_Gatehouse]

If you can settle for "mostly flat" i.e. flat enough to sit on or lie on, just use a 1/8" thick turnbutton made of delrin, fiberglass or something similar.

[jbo_c]

Another good idea, Evan. Thanks. Didn’t realize they were available that thin.

Thanks.

Jbo

[fallguy1000]

I built 3 flush deck lids, plus two in a benchtop and one edge drain type.

They are made with aquaplas. Tons of work to build.

Basically, a gutter is formed. The inside edge of the gutter is the landing for the lid. There is a gasket made from 0.250" rubber surg tube. Things must be sized so the gutter gasket and lid and deck are all flush.

Hardware is all by gemlux. Compression latches in stainless.

Lots and lots of iterations, fairing, tabbing. They are still not done!

The gutters have nylon barb fittings that go to tees and out to a thru hull.

I custom built a router from a dremel tool for cutting in the gaskets..

I can't add pictures to this forum.

If you want more details about this super slow and painful method, let me know.

The gutters are made with aquaplas 3/4" hd core and plenty of 1708 glass. They are epoxy bonded to the hull and then tabbed in because people will walk on them.

I recommend minimizing the amount of flush decks. This can be done by accessing lockers from the sides and using off the shelf access panels.

I still am trying to fair one of the openings this week, but they might end up getting done next April as the boat is out in the cold...