Lewmar Hatches.. Seal Kits

Asssuming this is the same design as on my old 1996 boat, the big problem is getting the old sealant out of the groove in the hatch frame. I bought a set of dental picks to help but it still tends to snap back.

Best tip I had was to ditch the Lewamr seals altogether and buy some round 8mm neoprene rubber cord (available from Seals Direct, at about £2 per hatch). This can be stuck/sealed into the internal corner of the frame with suitable sealant, takes minutes and is a doddle to replace every few years if needed.
 
Any hints or tricks for fitting the new seal?

The patience of an angel. Do read the instructions that come with it thoroughly and don't skip the "drop of superglue in each corner" step. Don't stretch the seal as you work your way around it, especially in the corners - else you'll end up with a too long side and have to start all over again. It's much easier with the hatch removed. Bring a large vocabulary of curses.
 
I renewed the acrylic glass at the same time. The seal is really awkward to position properly, especially around the corners. After 21 hatches I thought I had it mastered ....... until the 22nd that is!��

The old sealant can be removed by using flat screwdrivers like chisels (they won't dig into the aluminium), and turps to clean the frame up.

Good luck. It is possible, but only with patience.
 
The bad news is that sometimes (as happened with us), the frame may be slightly warped and you will never get a good seal. The only solution was to get a completely new hatch :disgust:
 
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