2009 Chall. 180 SE Storage Hatch Problem

[seadooguynj]

Hey all,

Dropped my 09 Challenger 180 SE 255 HP off at the dealer today for service. The starboard (drivers side) of the boat's rear storage hatch/engine compartment hatch has gel coat that is bubbling in several areas. The dealer said they would contact BRP and see about a warranty replacement. So I am looking on ebay tonight and there are several of the same hatches with the same gel coat bubbling problems for sale. Does anyone know if this is a factory screw up when they made these hatches? Or what the deal might be?

Here is the link for an example of what I found in several places on ebay:

http://www.ebay.com/itm/170519336876?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

 

[James.Moon]

I haven't noticed any such problems with my boat which is same 2009 180SE 255 as yours. I did have a cavitation on WOT problem which was a factory defect (ride plate not sealed properly). I found it out on this forum and after some extended dialogue with my dealer, got it fixed on warranty.

 

[jkoziol]

Hi just bought a support challenger 40 hrs. Darn thing lost power first trip out its at the dealer. I did not notice gel coat bubbles. But mine do stick. Not sure if you experienced trouble opening them?

 

[seadooguynj]

No they both open fine, just the gel cote defect on the starboard side. Thanks for the info.

 

[dothadoo]

Okay, here is the deal with the bubbles. Those hatches are made using a process called LRTM, or Light Resin Transfer Molding. The way it works is the is a mold on top and a mold on the bottom with the resin introduced around the edge and sucked out to the middle with a vacuum. Normally, it is a very good and clean process, provided the molds have no leaks. The bubbles come from air leaks in the seal or the mold itself. As the resin cures, it off gasses and if there are any bubbles, they will become larger. This is fairly easy to detect and should have been caught by the QA inspectors at the factory, and in turn, fixed in the lamination department. If you were to knock on different sections of the hatch, everything should sound solid. If it sounds hollow, that is a bubble. This should, IMO, have a lifetime warranty on the fiberglass parts, as that is a structural issue. I understand that it is only a hatch and you probably will not be walking on that hatch, but they should have never let that get to the production line. I am sure that it will fall under the standard warranty though.

I was a fiberglass engineer at two different boat manufacturers and it was my job to bring in the closed molding process to both of these plants and improved on the quality of parts made. If you have any more fiberglass related issues, please let me know and I will be happy to tell you what I know.

 

[seadooguynj]

Okay, here is the deal with the bubbles. Those hatches are made using a process called LRTM, or Light Resin Transfer Molding. The way it works is the is a mold on top and a mold on the bottom with the resin introduced around the edge and sucked out to the middle with a vacuum. Normally, it is a very good and clean process, provided the molds have no leaks. The bubbles come from air leaks in the seal or the mold itself. As the resin cures, it off gasses and if there are any bubbles, they will become larger. This is fairly easy to detect and should have been caught by the QA inspectors at the factory, and in turn, fixed in the lamination department. If you were to knock on different sections of the hatch, everything should sound solid. If it sounds hollow, that is a bubble. This should, IMO, have a lifetime warranty on the fiberglass parts, as that is a structural issue. I understand that it is only a hatch and you probably will not be walking on that hatch, but they should have never let that get to the production line. I am sure that it will fall under the standard warranty though.

I was a fiberglass engineer at two different boat manufacturers and it was my job to bring in the closed molding process to both of these plants and improved on the quality of parts made. If you have any more fiberglass related issues, please let me know and I will be happy to tell you what I know.

I am out of regular warranty at this point but I am covered by BEST. Do you think if I write a nice letter to BRP explaining the situation and my disappointment and include photographs as well as printouts of other defective hatches on eBay that they would do anything for me? All I'm really looking for is just a new hatch. I'll even install it myself and ship the old one back. I'm not looking to get one over on them, I just want the right thing done here and if this defect is what you describe, and I strongly suspect that it is now that you explained it to me, then they should step up and earn my repeat business and send a new hatch. Just my two cents, but I suspect they will probably do nothing.