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Companionway hatch leak

scundy2

scundy2

Steve Cundy
My 1979 382's companionway hatch has developed a leak around the aft port corner.
I believe that's automotive safety glass in the hatch, but I have no idea what was used to fasten and seal the glass to the fiberglass/plywood hatch.

I apologize for the poor quality of the attached pictures. It appears that water is coming through the plywood and dripping into the galley. I dried the top of the hatch and it appeared that water was collecting in the channel surrounding the glass and finding its way to a weak spot in the seal.

I tried taping over the channel with Gorilla Tape, but now it's leaking even worse.

Does anybody know how to seal the glass to the hatch (gel coat over 1/2" marine plywood)? The exposed edge of the plywood (around the glass inside the cabin) was not even epoxied, which is probably a good thing, since I would never have had a clue that the plywood was soaking wet.

BTW, I recently upgraded from a 5000 btu air conditioner to an 8000 btu one.

Thanks in advance!
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Consider butyl tape Steve. Its readily available locally as its used to seal auto windshields. It stays somewhat soft & pliable and sticks to anything and everything. New Found Metals supplies it with their replacement ports FWIW. If you're looking for a finished bead around the glass, auto butyl might not be the best choice (not sure). But butyl is what is put in between teak strips on teak decks. Teak is taped, butyl in the groove, and its struck with a putty knife to smooth the surface. Wear gloves and have solvent and rags. It will get everywhere.
 
I re-bed my both genny tracks when I replaced the wood caps. 30+ holes for each track. No leaks. When you are looking to seal only, not having any adhesive quality, butyl is my go to sealent.
 
Steve are you certain you are not dealing with increased condensation from the increase in size / output of new AC Unit? Have you hose tested the area to identify the location of the leak?
 
Jeff, yes I considered the possibility that the increased BTU's would probably increase the condensation both outside the hatch and on the inside, too.

However, in the few days since I applied the tape over the channel, the leaking has completely stopped and the inside of the hatch is bone dry while the outside of the hatch is drenched with morning dew/condensation.Therefore, I'm going to consider other sources (e.g., leak) for the cause of the water.

Also, I have been air conditioning (e.g., dehumidifying) the boat continuously since April and the air is very dry inside the boat. There is no evidence of condensation anywhere inside the boat. I have not yet hose tested the hatch, but it's on the list. Initially, there was a large amount of condensed moisture from the air conditioner that I collected in a large pot - until I adjusted the air conditioner's yaw so that it would drain outside the cabin.

Thanks, Jeff!
 
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