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.
Touring Kayak Paddles
Kayak Deck Gear Bags
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