WHY WOULD I NEED FIBERGLASS AND RESIN?
I'M ONLY REDOING THE WOOD, FOAM, AND VINYL.
DOES ANYONE KNOW WHERE I CAN GET VINYL THATS WIDER THAN 36"? MY HATCH IS ABOUT 42"X82".

Just as a reference, I just did this on my Warlock.

I spent about $100 on some quality wood, cut it and epoxied it all together using stainless screws.

I spent about $70 on fiberglass and resin and glassed it all real nice.

Then I painted it with white epoxy paint - about $40

Then I took it to an Upholstery guy and paid $140 for him to glue the foam down and upholster the topside.

I'd say it was overkill with all the glass and paint, but it turned out really nice and should last forever. The upholstery guy said it was one of the best made engine covers he's seen.

Oh yeah, I threw a Harwood scoop on it too for about $150.

Real slick for about $500. I'd say you could cut a lot of the cost out by just using good plywood and giving it a couple coats of resin. Then upholster it.

I'm assuming you need to make a new wood cover because of the dry-rot. Mine had pretty much disintigrated where the hinges and gas springs screwed in and it wasn't worth trying to reuse it.

-Steve

You need to do exactly what sgr said. If you want it to last, fiberglass the flat portion of the wood and at least double coat the edges w/resin. Always champher the plywood on the edges where the material/foam will fold over.

[b][i]so Sgr Where Did U Get Your Foam And Vinyl From? I'm Trying To Find Some Good Vinyl For A Decent Price. Thanks For All Your Assistance.

CaptChucky, I'm doing an interior also. I have been looking online for vinyl and found prices between 9 and 35 dollars a yard. Here is a thread with some vinyl sources. http://www.offshoreonly.com/forums/s...ad.php?t=83852 I also sent off for a catalog from the Astrup Company for thread staples etc. I haven't started yet other than measuring to find out how much matierial I need.

The Upholstery guy ordered it when he did the job. It was Newport marine vinyl (Mellohide). Most upholstery places will charge up to $18/yard, but I've seen it on the internet for about $10/yard. Upholstery shops will sell you the material if you don't feel like searching all over the internet.

I never dealt with this place, but found this link.
http://store.autocarpets.com/vinyl--...mellohide.html

There are a lot more colors available than what they show.

The newport vinyl has good UV protection and is mildew resistant.

-Steve

Try this place. I never ordered from them, but they look like they have a bunch of stuff.
http://www.beaconfabric.com