SteveSgt
Senior Member
I have interior lithium batteries, so I don't believe I need the two battery vents (unless I move to Canada). I have a modification plan to replace those vents with a connector panel for WiFi, Ethernet, ham radio, and AM/FM/TV.

The best hatch I've found is about 0.75" smaller than the opening for the two battery vents. So I will have to enlarge the width of the hole, and somehow patch the fiberglass to reduce the height of the hole.
Question #1: How would you fill a 2"W by 0.75"H bottom edge of a round hole? I think I can hide it behind the flange of the new hatch, but I need something to screw-into and something to seal to. I'm prepared to climb the fiberglass and gelcoat learning curve if that's my only option, but I thought perhaps I could do something like epoxy-in a carefully carved piece of white 1/4" ABS plastic.
Question $2: What tool would you use to enlarge the hole horizontally? I have hack saws and I have a very old jigsaw. I also have a Dremmel router and grinder. Or do I need something else?
I'm thinking I would also epoxy a couple of strips of 1"x2" wood to give something sturdy to screw the hatch into two sides of the hull.
What would the experts do?

The best hatch I've found is about 0.75" smaller than the opening for the two battery vents. So I will have to enlarge the width of the hole, and somehow patch the fiberglass to reduce the height of the hole.
Question #1: How would you fill a 2"W by 0.75"H bottom edge of a round hole? I think I can hide it behind the flange of the new hatch, but I need something to screw-into and something to seal to. I'm prepared to climb the fiberglass and gelcoat learning curve if that's my only option, but I thought perhaps I could do something like epoxy-in a carefully carved piece of white 1/4" ABS plastic.
Question $2: What tool would you use to enlarge the hole horizontally? I have hack saws and I have a very old jigsaw. I also have a Dremmel router and grinder. Or do I need something else?
I'm thinking I would also epoxy a couple of strips of 1"x2" wood to give something sturdy to screw the hatch into two sides of the hull.
What would the experts do?