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They would of used Lexan as it would of had the strength to take that load and the shock of being slammed shut. I took a look at mine this weeken and I can see what you are looking at.
There are many good sites on the internet to teach you how to mold something in fiberglass. It is really simple if you take teh time to practice a bit.
You can make the mold out of fiberglass just glue the broken pieces together...wrap in saran wrap (to release) and mold new fiberglass mat about the outside. One cured you can pull apart and then you have a good mold of the old hatch.
Take the mold and build up the new hatch with stringers in the mold. Use Saran wrap on this so you can het it to release from the mold. Email me at kfmaclachlan@yahoo.com and we can discuss this in detail.
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