The skin was attached using Loctite PL Premium construction adhesive. This was used instead of glue because the fit is not tight enough for traditional wood glue to bond correctly.
I needed to stretch the 1/8″ birch panel to the inside of the hatch so it didn’t deform the ribs and then become permanent when the PL Premium dried. I used a tie down strap to ensure the contour remained correct while the PL Premium dried. The inside hatch skin was cut a bit larger than necessary so I could come back and use a flush trim bit on a router to even it up perfectly.
After the skin was trimmed.
Dry fitting the hatch to make sure the contour was still correct.
A better view of the gap for the hatch struts.
The hurricane was then cut down to size leaving 3/8″ extended over the edge on both sides for proper water drainage. The extension at this point is 1/2″ to allow for the outside skin thickness.
Drilling the pilot holes to fit the the hinge on the trailer. The hols were spaced 12″ apart for fitting but later the amount was doubled to 6″ spacing for the final install.
Here you can see the 3/8″ gap while the hinge is in the closed position.
Here you can see the positioning of the struts and the need for the reinforcement on the hatch in this area.
The galley lights were installed so they didn’t come into contact with the counter top.