Building Searay 380DA Fiberglass Hardtop

Henry:...yes, I thought of a hatch (prices are ridiculous....) but I am confident that even with a similar size rear hardtop that I can still reach the center of the arch.

As part of the top building process, I have made a crude custom ladder that hugs the arch from the side deck and allows me to get to the very center of the arch and top. The tops are also strong enough to walk on if required.

If I find a deal on a quality 20" x 20" hatch I made add it in the future to the forward top....
 
I’d say finesse the side ladder concept. When I can’t get to stuff through the hatch I’ve had to lug a ladder to the boat, that in our slip can be a challenging experience. A removable “fixed” ladder would definitely work much better. Mounts on both sides would also make cleaning and waxing easier. I apologize for not saying it earlier, but the had top looks really good.
 
Looks great, may have missed this but how are you planning on finishing the undersides?
It depends on how hard it will be to fair etc....currently it is just the Chopped Strand Mat showing...If its not too bad I may fair and paint.
If it is too much, then I may do a light fairing and paint with something like KIWI non-skid or other high hiding texture paint.
 
I’d say finesse the side ladder concept. When I can’t get to stuff through the hatch I’ve had to lug a ladder to the boat, that in our slip can be a challenging experience. A removable “fixed” ladder would definitely work much better. Mounts on both sides would also make cleaning and waxing easier. I apologize for not saying it earlier, but the had top looks really good.
In my previous life, I was a sailboat rigger and climbed up and down masts for a living. There are many types of mast steps etc that may be applicable. Perko used to make a really nice SS folding step that could be installed on the arch.
 
I am not far from Palm Coast and looking for a beach home in the area. Probably closer towards Daytona but would love to see what you did since I am designing on for my 390 ec
 
Pics of 1/4" 6061 T-6 Aluminum plate with S.S. 1/4"-20 bolts tapped ready to be embedded in epoxy to the underside of the hardtop. These will serve as the mounting points for the hardtop struts.

Balsa Core was removed so that it wouldnt get crushed.
IMG_1146[919].jpg
IMG_1147[918].jpg
 
One of six places where the Balsa Core was removed from edge of hardtop (3" deep by 3" wide) to accept a 3/8" fiberglass tab (made of alternating layers of CSM and 1708 fabric) that will be epoxied in place. Tab will extend about 4" past the edge of the hardtop.

Tabs will align with slots in radar arch and then be glued in place with Plexus MA350.
Hard to tell in photo but Balsa Core along the edge has been sanded back into a radius so that it can be sealed with epoxy.
IMG_1148[917].jpg
 
Gorgeous. I suggest putting a stainless grab rail along the edge for safer moving forward. Maybe you could move the ones on the top of the side window frames up?
 
Yeah, one of my neighbors who also has a Sabre mounted steps the look like bar mounted bottle openers to one of the windshield pillars.
Maybe these?
6594170.jpg
 
Yup.....was looking at those too (cheaper than the Perko folding ones)
 
Yup.....was looking at those too (cheaper than the Perko folding ones)
I have used those folding ones on my last boat that had a walk thru windshield but no steps to get up on the helm. They are quite sturdy and worked well.
 
Pics of fiberglass tabs (about 5/16" thick x 3" wide made out of 1708 Biax) epoxied in to edge of the hardtop that will mate to a slot in the radar arch. The balsa core at the edge of the hardtop has been removed and filled with thickened epoxy to finish the edge and seal the balsa core. The tabs will be glued in to the arch with Plexus MA530. The Plexus is used in boat production to glue fiberglass stringers to the fiberglass hull. It etches the resin and makes an incredibly strong bond.

Tomorrow I dry fit the top to the arch and make the slots in the hardtop.
IMG_1156[929].jpg
IMG_1155[928].jpg
IMG_1156[929].jpg
IMG_1155[928].jpg
 
Keep plugging along (it helps keep my mind off of the news!!)
Fairing the underside of the hardtop with Epoxy fairing compound
IMG_1164[1007].jpg
 

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