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Doyle, When I cut the hatches on my son's Cape Charlie I used a utility knife. First layout the hatch with masking tape and cut along a straight edge slowly, first to score the ply, then repeated cuts going with more pressure. In about 5 minutes it was done and it was a very close fit. To finish off the flush hatch I used a the silicone and Handi-wrap method to make a tight seal. I learned that from model rc boating. I hope this helps.. Rick
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Guillemot Kayak - High
Performance Wooden Sea Kayak Designs
