http://www.topkayaker.net Posted by: FrankNC on Jan-02-13 8:42 PM (EST)
Tom sells the screw in hatch kits so that part is easy. His site has an article about making your own hatch. Basically you make a mold from paper mache or other material if you do not have another hatch you can use to make a mold. Then you make a fiber glass hatch you can gelcoat or just paint after it is finished. If you use basic polyester resin and a combination of fiberglass mat and woven cloth it should cost you less than $40 in materials.