The Post (not mine)
Update, Dec 26/22
After spending way too many hours stripping, scraping, wire brushing and cleaning up the mess I brought the hatches to a local powder coating shop, who sandblasted and powder coated the 6 pieces for C$150. Sometimes that's how it goes. They look great. This is my first experience with powder coating, I hope the finish is a durable as the original.
Turns out they aren’t anodized but likely powder coated. Removing this stuff with todays non-lethal paint strippers is incredibly time consuming. This took strippers and various types of wire wheels/brushes and many many hours. There has to be a better way…
Windstar’s hatches have stood up very well over her nearly 40 year life however they were showing their age with crazed plexiglass, hardened seals and weathered anodizing.
Apparently current production (2022) Lewmar ocean series hatches will fit, however the cost is significant and I do wonder if they will last 30+ years like the originals.
The original hatches appear to be of very good quality, and refurbishment does not seem to be too difficult.
The hatches will need to be:
Unfortunately the roll pin is in a blind hole, I cant drift it through. With that in mind I tightened the nut on the shaft to allow for some clearance, and used a small pin punch to try to drift the key southwards. To my surprise, the entire arm shifted - it was not threaded on as I thought, though it is a close fit, made even closer by 40 years of marriage. I then put a drop of oil on the threads and let it work its way down the threads and keyway and used that same nut to push the lever off. So, problem solved! They were snug and one was a bit galled but no damage.
As found, the shaft height above the lever.
More cleverness! The outside knob/wheel is stood off of the surface of the plexiglass by the stainless washer above but also the black plastic washer below, plus the top hat bushing. The lot is installed while the silicone is wet, before it cures. Note the counterbore in the lens.
After that, the disassembly process was straightforward though some mechanical aptitude is required.