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INSTALLATION MANUAL

Lewmar's fitting guide for Low Profile, Medium Profile and Ocean hatches and Standard, Atlantic and Stainless portlights: cut-out dimensions, fastenings, step-by-step fitting and the CE area each one is approved for.

DocumentLewmar Hatch & Portlight Fitting Guide
FormatPDF · 16 pages · 0.7 MB
LanguageEnglish
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PlanningHatch SizesPortlight SizesFittingCE AreasRoller ShadeProducts
Lewmar Hatch & Portlight — Fitting Guide

Before You Cut

  • Mounting surface must be flat to ±1 mm.
  • Replacing an older Lewmar unit: standard cut-out sizes have not changed, but corner radii have on some models. If nothing matches, build an intermediate timber frame.
  • Hatches and portlights are not stiffening members: stiffen the deck against distortion in heavy weather. Cutting holes can compromise the structure – if in doubt consult a designer or surveyor.
  • Seal exposed GRP laminate before fitting; deburr metal decks; insulate the lower frame if electrolytic corrosion with the aluminium frame is possible.
  • Hatch lids must open past 90° to fasten the frame. A fully open lid should rest supported near its handle edge, not near the hinges.
  • Fitting a Trimkit: increase the hatch cut-out by 3 mm.
  • Tools: silicone bedding compound and gun, drill and bits, jigsaw, screwdrivers/Allen keys/spanners, compass for the corner radii, felt pen, ruler.

Hatch Specifications & Cut-Outs

Low Profile hatch

Part no. Size Length X Width Y Height Z Radius R Cut-out X1 Cut-out Y1 Cut-out R1
39900030 00 281
1 11/16 (as printed)" 		281
1 11/16 (as printed)" 		25
1" 		72.5
2 7/8" 		211
8 5/16" 		211
8 5/16" 		42.5
1 11/16" 		View →
39903030 03 246
9 11/16" 		301
11 7/8" 		25
1" 		72.5
2 7/8" 		176
6 15/16" 		231
9 1/8" 		42.5
1 11/16" 		View →
39910030 10 330
12" 		330
12" 		25
1" 		72.5
2 7/8" 		260
10 1/4" 		260
10 1/4" 		42.5
1 11/16" 		View →
39920030 20 272
10 11/16" 		417
16 7/16" 		25
1" 		72.5
2 7/8" 		202
7 15/16" 		347
13 11/16" 		42.5
1 11/16" 		View →
39930030 30 397
15 5/8" 		527
20 3/4" 		25
1" 		72.5
2 7/8" 		327
12 7/8" 		457
18" 		42.5
1 11/16" 		View →
39940030 40 491
19 5/16" 		491
19 5/16" 		25
1" 		72.5
2 7/8" 		421
16 9/16" 		421
16 9/16" 		42.5
1 11/16" 		View →
39941030* 41 246
9 11/16" 		491
19 5/16" 		25
1" 		72.5
2 7/8" 		176
6 15/16" 		421
16 9/16" 		42.5
1 11/16" 		View →
39944030 44 512
20 3/16" 		512
20 3/16" 		25
1" 		72.5
2 7/8" 		442
17 3/8" 		442
17 3/8" 		42.5
1 11/16" 		View →
39950030 50 447
17 5/8" 		577
22 11/16" 		25
1" 		72.5
2 7/8" 		377
14 13/16" 		507
19 15/16" 		42.5
1 11/16" 		View →
39954030 54 462
18 3/16" 		577
22 11/16" 		25
1" 		72.5
2 7/8" 		392
15 7/16" 		507
19 15/16" 		42.5
1 11/16" 		View →
39960030 60 577
22 11/16" 		577
22 11/16" 		25
1" 		72.5
2 7/8" 		507
19 15/16" 		507
19 15/16" 		42.5
1 11/16" 		View →
39965030* 65 560
22 1/16" 		675 max / 560 min
26 9/16" / 22 1/16" 		25
1" 		72.5
2 7/8" 		See drawing See drawing 42.5
1 11/16" 		View →

Lewmar Low Profile hatch size 65 trapezoid cut-out drawing

Medium Profile hatch

Part no. Size Length X Width Y Height Z Radius R Cut-out X1 Cut-out Y1 Cut-out R1
39930020 30 397
15 5/8" 		527
20 3/4" 		32
1 1/4" 		78
3 1/16" 		327
12 7/8" 		457
18" 		42.5
1 11/16" 		View →
39940020 40 492
19 3/8" 		492
9 3/8 (as printed)" 		32
1 1/4" 		78
3 1/16" 		421
16 9/16" 		421
16 9/16" 		42.5
1 11/16" 		View →
39944020 44 513
20 3/16" 		513
20 3/16" 		32
1 1/4" 		78
3 1/16" 		442
17 3/8" 		442
17 3/8" 		42.5
1 11/16" 		View →
39950020 50 448
17 5/8" 		578
22 3/4" 		32
1 1/4" 		78
3 1/16" 		377
14 13/16" 		507
19 15/16" 		42.5
1 11/16" 		View →
39954020 54 463
18 1/4" 		578
22 3/4" 		32
1 1/4" 		78
3 1/16" 		392
15 7/16" 		507
19 15/16" 		42.5
1 11/16" 		View →
39960020 60 578
22 3/4" 		578
22 3/4" 		32
1 1/4" 		78
3 1/16" 		507
19 15/16" 		507
19 15/16" 		42.5
1 11/16" 		View →
39970020 70 698
27 1/2" 		698
27 1/2" 		32
1 1/4" 		78
3 1/16" 		627
24 11/16" 		627
24 11/16" 		42.5
1 11/16" 		View →
39977020* 77 770
30 5/16" 		770
30 5/16" 		32
1 1/4" 		78
3 1/16" 		699
27 1/2" 		699
27 1/2" 		42.5
1 11/16" 		View →

Ocean hatch

Part no. Size Base Length X Width Y Height Z Radius R Cut-out X1 Cut-out Y1 Cut-out R1
39600050* 0 Flat base 275
10 13/16" 		275
10 13/16" 		39.5
1 9/16" 		69
2 11/16" 		201
7 15/16" 		201
7 15/16" 		34
1 5/16" 		View →
39600070* 0 Flange 25 mm (1") 206
8 1/8" 		206
8 1/8" 		36.5
1 7/16" 		View →
39610050 10 Flat base 324
12 3/4" 		324
12 3/4" 		39.5
1 9/16" 		75
2 15/16" 		255
10 1/16" 		255
10 1/16" 		40
1 9/16" 		View →
39610070 10 Flange 25 mm (1") 260
10 1/4" 		260
10 1/4" 		42.5
1 11/16" 		View →
39620050 20 Flat base 266
10 1/2" 		411
16 3/16" 		39.5
1 9/16" 		69
2 11/16" 		197
7 3/4" 		342
13 7/16" 		34
1 5/16" 		View →
39620070 20 Flange 25 mm (1") 202
7 15/16" 		347
13 11/16" 		36.5
1 7/16" 		View →
39630050 30 Flat base 391
15 3/8" 		521
20 1/2" 		39.5
1 9/16" 		75
2 15/16" 		322
12 11/16" 		452
17 13/16" 		40
1 9/16" 		View →
39630070 30 Flange 25 mm (1") 327
12 7/8" 		457
18" 		42.5
1 11/16" 		View →
39640050 40 Flat base 485
19 1/8" 		485
19 1/8" 		39.5
1 9/16" 		75
2 15/16" 		416
16 3/8" 		416
16 3/8" 		40
1 9/16" 		View →
39640070 40 Flange 25 mm (1") 421
16 9/16" 		421
16 9/16" 		42.5
1 11/16" 		View →
39644050 44 Flat base 509
20 1/16" 		509
20 1/16" 		43
1 11/16" 		76
3" 		437
17 3/16" 		437
17 3/16" 		40
1 9/16" 		View →
39644070 44 Flange 25 mm (1") 442
17 3/8" 		442
17 3/8" 		42.5
1 11/16" 		View →
39650050 50 Flat base 444
17 1/2" 		574
22 5/8" 		43
1 11/16" 		76
3" 		372
14 5/8" 		502
19 3/4" 		40
1 9/16" 		View →
39650070 50 Flange 25 mm (1") 377
14 13/16" 		507
19 15/16" 		42.5
1 11/16" 		View →
39654050 54 Flat base 459
18 1/16" 		574
22 5/8" 		43
1 11/16" 		76
3" 		387
15 1/4" 		502
19 3/4" 		40
1 9/16" 		View →
39654070 54 Flange 25 mm (1") 392
15 7/8" 		507
19 15/16" 		42.5
1 11/16" 		View →
39660050 60 Flat base 574
22 5/8" 		574
22 5/8" 		43
1 11/16" 		76
3" 		502
19 3/4" 		502
19 3/4" 		40
1 9/16" 		View →
39660070 60 Flange 25 mm (1") 507
19 15/16" 		507
19 15/16" 		42.5
1 11/16" 		View →
39670050 70 Flat base 694
27 5/16" 		694
27 5/16" 		43
1 11/16" 		76
3" 		622
24 1/2" 		622
24 1/2" 		40
1 9/16" 		View →
39670070 70 Flange 25 mm (1") 627
24 11/16" 		627
24 11/16" 		42.5
1 11/16" 		View →
39677050 77 Flat base 767
30 3/16" 		767
30 3/16" 		43
1 11/16" 		76
3" 		694
27 5/16" 		694
27 5/16" 		40
1 9/16" 		View →
39677070 77 Flange 25 mm (1") 699
27 1/2" 		699
27 1/2" 		42.5
1 11/16" 		View →

Low and Medium Profile lower frame flange: 15 mm (9/16"). Fasten the hinge section with M6 (1/4") bolts and the lower frame with 5 mm CSK screws (No. 10 UNC, 2BA). Backing plate part numbers 360061909 (M6) or 360062909 (1/4"). * = made to order. Cut-out sizes change if Trimkits are used.

Portlight Specifications & Cut-Outs

Standard portlight (opening)

Part no. Size Width X Length Y Height Z Radius R Cut-out X1 Cut-out Y1 Cut-out R1
393020200 0 176
6 15/16" 		323
12 11/16" 		4
5/32" 		62
2 7/16" 		156
6 1/8" 		303
11 15/16" 		52
2 1/16" 		View →
393120200 1 191
7 1/2" 		367
14 7/16" 		4
5/32" 		62
2 7/16" 		171
6 3/4" 		347
13 5/8" 		52
2 1/16" 		View →
393180200 1RE 191
7 1/2" 		367
14 7/16" 		4
5/32" 		95
3 3/4" 		171
6 3/4" 		347
13 5/8" 		85.5
3 3/8" 		View →
393220200 2 176
6 15/16" 		425
16 3/4" 		4
5/32" 		62
2 7/16" 		156
6 1/8" 		405
15 15/16" 		52
2 1/16" 		View →
393320200 3 191
7 1/2" 		449
17 11/16" 		4
5/32" 		62
2 7/16" 		171
6 3/4" 		429
16 7/8" 		52
2 1/16" 		View →
393420200 4 191
7 1/2" 		646
25 7/16" 		4
5/32" 		62
2 7/16" 		171
6 3/4" 		627
24 11/16" 		52
2 1/16" 		View →
393460200* 4L 195
7 11/16" 		708
27 7/8" 		4
5/32" 		62
2 7/16" 		175
6 7/8" 		688
27 1/16" 		52
2 1/16" 		View →
393440200* 4R 195
7 11/16" 		708
27 7/8" 		4
5/32" 		62
2 7/16" 		175
6 7/8" 		688
27 1/16" 		52
2 1/16" 		View →
393520200 5 264
10 3/8" 		449
17 11/16" 		4
5/32" 		62
2 7/16" 		244
9 5/8" 		429
16 7/8" 		52
2 1/16" 		View →
393780200* 7RE 191
7 1/2" 		425
16 3/4" 		4
5/32" 		95.5
3 3/4" 		171
6 3/4" 		405
15 13/16" 		85.5
3 3/8" 		View →

Atlantic portlight (opening)

Part no. Size Width X Length Y Height Z Radius R Cut-out X1 Cut-out Y1 Cut-out R1
39110090 10 174
6 7/8" 		304
12" 		6
1/4" 		71
2 13/16" 		154
6 1/16" 		284
11 3/16" 		61
2 3/8" 		View →
39130090 30 200
7 7/8" 		400
15 3/4" 		6
1/4" 		71
2 13/16" 		180
7 1/16" 		380
14 15/16" 		61
2 3/8" 		View →
39132090 32 200
7 7/8" 		400
15 3/4" 		6
1/4" 		100
3 15/16" 		180
7 1/16" 		380
14 15/16" 		90
3 9/16" 		View →
39140090* 40 200
7 7/8" 		480
18 7/8" 		6
1/4" 		71
2 13/16" 		180
7 1/16" 		460
18 1/8" 		61
2 3/8" 		View →
39160090* 60 200
7 7/8" 		600
23 5/8" 		6
1/4" 		71
2 13/16" 		180
7 1/16" 		580
22 13/16" 		61
2 3/8" 		View →

Stainless portlight (opening)

Part no. Size Width X Length Y Height Z Radius R Cut-out X1 Cut-out Y1 Cut-out R1
393820862 8 196
7 11/16" 		452
17 13/16" 		1.5
1/16" 		n/a – – – View →

Portlights come with 12 M5 × 25 mm screws for hull thickness 17–25 mm. Maximum hull thickness 34 mm (1 3/8"), minimum 7 mm (1/4"); near the maximum the opening may be restricted. Standard portlight part numbers ending 200 are white trim; ivory trim ends in 500. Size 4 left/right Standard portlights have no flyscreen. * = made to order.

Standard portlight cut-out templates

Lewmar Standard portlight cut-outs sheet 1, reduced view

Lewmar Standard portlight cut-outs sheet 2, reduced view

Print the PDF pages at 1:1, join the two parts along line A–A and check every measurement before cutting – Lewmar gives the cut-outs as a guide only.

Hatch fitting

  • Removing an old hatch: bridge a timber across a frame corner (pad the deck), put a second piece under the inside frame and pull them together with a G-clamp to lift the frame; cut the bedding with a thin knife. Remove all old sealant and fill old holes.
  • Mark the cut-out (plus trim allowance), radius the corners with a compass, offer the hatch up to check.
  • Drill a jigsaw start hole on the waste side and cut; a hole cutter matching the corner radius can do the corners. Watch for cables, gas pipes and other services.
  • Test fit, mark the lower frame holes, remove and drill. Through-bolt the hinge area; self-tappers are fine for the rest of the frame.
  • Run a generous bead of bedding compound round the frame and seal both sides of each fastening hole; refit so a little compound squeezes out all round; fasten and clean up.

Portlight fitting

  • Cut out the paper template, check it against the back of the portlight, tape it on and mark the cut line.
  • Drill a start hole on the waste side and jigsaw the aperture; trim or remove headlining if needed.
  • The outer frame is clamped to the hull by the inner frame inside the boat: test fit with the clamp ring before sealing.
  • Fill any old holes, bed the frame generously, refit so compound squeezes out all round, clamp outer to inner frame with the supplied fixings (grease the threads) and clean up.

Hatch vent

  • Fits hatch lid or deck (trim not included for deck fitting); deck thickness up to 100 mm; no sealant needed.
  • Cut acrylic from both sides: tape the template clear of handles and stays, drill a pilot, cut with an 80 mm (3") hole saw from each side, drill 6 mm (1/4") fastening holes from both sides, supporting the lid.
  • Assemble with internal parts, O-rings and seal, fit and fasten from inside. For deck fitting, break through the blanked top-down holes, seal the screws and use other fixings; trim part number 361042992.

CE Area Approvals

Product Sizes CE area
Low Profile hatch All 2
Medium Profile hatch All 2
Ocean hatch All 2
Standard portlight, fixed 0, 1, 1RE & 2 1
Standard portlight, fixed 3, 4, 4L, 4R & 7RE 2
Standard portlight, opening All 2
Atlantic portlight, fixed All 1
Atlantic portlight, opening 10, 30, 32 1
Atlantic portlight, opening 40, 60 2
Stainless steel portlight 8 2

Area 1: hull sides above the waterline. Area 2: other areas where people walk or step. Area 3: other areas, e.g. superstructures. Area 4: parts of Area 3 protected from direct sea impact. A product approved for an area may be fitted to all lower categories. Lewmar warranty is void if fitted outside its approved area. Products comply with ISO/DIS 12216.2(E) and Directive 94/25/EC.

Roller Shade/Screen for Hatches

Hatch size Trim & roller screen Trim only Roller screen only Length A Width B
10 367710252 368710252 367710972 398
15 11/16" 		345
13 9/16"
20 367720252 368720252 367720972 340
13 3/8" 		432
17"
30 367730252 368730252 367730972 465
18 5/16" 		542
21 5/16"
40 367740252 368740252 367740972 559
22" 		506
19 15/16"
44 367744252 368744252 367744972 580
22 13/16" 		528
20 13/16"
50 367750252 368750252 367750972 515
20 1/4" 		592
23 5/16"
54 367754252 368754252 367754972 531
20 7/8" 		592
23 5/16"
60 367760252 368760252 367760972 645
25 3/8" 		592
23 5/16"
70 367770252 368770252 367770972 765
30 1/8" 		712
28"

Integral blind and flyscreen with trickle ventilation, for standard Lewmar hatches.

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