I need to build a new engine hatch for my Cobra. It is about 3' by 6' and flat. What is the best material to use? How thick do I need-it is supported around the edges? Where can I buy it? The hatch will be upolstered and wrap around the edges. We want to be able to walk and lay on it.

Baltek makes sheets of balsa wood laminated with fiberglass. They call it Decolite. It comes in various thicknesses like 3/8, 1/2. Put it together like plywood and glass over it.

My hatch is made from a foam sheet covered in a few layers of fiberglass and gel-cote, from the factory.

Here is all the stuff you need http://www.fibreglast.com/showproduc...0Cores-18.html

What he said. Mine are foam core, carbon fiber, fiberglass, epoxy: all, except foam, from the same source.
Due

NidaCore. A honeycomb panel with fiberglass on each side. Comes in various thicknesses, and should work well for your use. The attached picture is a thin strip of 1" thick NidaCore cut off the 4x8 sheet.

where can you get this stuff???

Michigan Fiberglass Sales in St.Clair Shores or Roseville Mich. sells Baltek products. They may also sell some of the foam core products.

Probably one of the cheapest companies to get your material from will be (composite one)... they have very good material but at a good price, we use there materials for our formula 1,2,&3 race boats. but a basic lay-up for a hatch is gelcoat, 2-3 layers of glass, balsa...any size you prefer, and then 2-3 more layers of glass....A wet lay-up will be heavier but if you had any way of vacuum bagging that will pull all of the excess epoxy out and make it alot lighter and stronger. if you need anything let me know...or look us up at
www.lambboats.com

does anyone make custom hatches?

If you wanna learn how, we are going to learn by trial and error in my garage this weekend!!!!