Over the past decade, catamaran owners and marine technicians have tackled escape hatch repairs using a range of techniques, materials, and philosophies -balancing safety, watertight integrity, aesthetics, and cost. Here’s a breakdown of the most common types of escape hatch repairs
(from forums, refit yards, insurance claims, and owner reports):

URGENT AND IMPORTANT

The loss of Pathfinder (thankfully without loss of life) in the Pacific has raised the safety issue of escape hatches in catamarans.
Pathfinder sank because an emergency escape hatch ‘blew out’ while under way. With a hole some three square feet just on the waterline, there is no bilge pump system that would be capable of dewatering the affected hull. While catamarans definitely float, they don’t float indefinitely, particularly when they have lost an emergency escape hatch. There have been other similar cases around the world.
The point of failure has been diagnosed as the reliance of the manufacturer of the hatch on the silicone bedding as the sole means of securing the hatch’s lens into the frame of the hatch.
Many catamaran manufacturers (including LAGOON, FOUNTAINE PAJOT, CATANA-BALI, and NAUTITECH) issued a recall notice for Goiot escape hatches in 2020, but owners may not have been reached by the recall notice, especially if they were not the first purchasers. (https://admin.catamarans-lagoon.com/sites/default/files/2023-11/Press-release-Goiot-escape-hatches-recall.pdf)

If you have a catamaran of any brand or vintage equipped with escape hatches you will want to ensure your escape hatches are indeed secure, and that any recall fix has been applied. There is also a cruiser-developed field expedient solution that can be applied to many hatches that was discussed on the cruisers forum website (https://www.cruisersforum.com/forums/f48/goiot-escape-hatch-42-49-recall-209310.html) in 2018, which consists of additional mechanical reinforcement of the hatch lens-to-frame attachment. I have added the images for that fix below.
Even if the recall has been applied, or if you have hatches that are not affected by the recall, you may want to consider reviewing your hatches, their construction and installation and ensuring you are satisfied that they are indeed appropriately secure to your personal satisfaction.

Escape Hatches – Recipe For Disaster | Gémeaux

A catamaran unlike a monohull has the possibility of overturning and not coming back rightside up. A monohull can turn over too, but it will always right itself as long as the keel is still attached. A catamaran has two stable positions, right side up and upside down. Because it is possible for the boat to turn in the inverted position with people inside the hull, European boat manufacturers have required the inclusion of escape hatches which can be used to exit an upside down boat. To insure the hatch is as high above the water as possible when the boat is inverted, the hatch is placed at the waterline when the boat is in the rightside up position. All this is well and good, but for most cruising catamarans it is very unlikely the boat will turn over.

🛠️ 1. Hatch Replacement (Like-for-Like or Upgrade)

What: Full removal and replacement with either an OEM (e.g., Lewmar, Goiot) or upgraded unit.
Why: Cracks in acrylic, hinge failure, UV degradation, or water ingress.
Pros: Restores factory integrity, easiest long-term solution.
Cons: Expensive, long lead times, not always an exact fit.
Popular upgrades: Switching from Goiot to Gebo, or from acrylic to Lexan/polycarbonate.

🧱 2. Resealing with Marine Sealant

What: Remove and reseal the hatch using Sikaflex 291, 3M 4200/5200, or Butyl tape.
Why: Water ingress from failed bedding compound or cracked flange.
Common Process: Clean all surfaces, apply new sealant, and reinstall with even torque.
Warnings: Improper prep leads to recurring leaks.

🛠️ 🪛 3. Acrylic/Polycarbonate Pane Replacement

What: Swap only the glazing panel in the frame.
Why: UV crazing, spider cracks, or delamination.
Tricky Part: Cutting to fit and rebedding without stress points.
DIY or Pro: Both done often; CNC cutting shops sometimes used.

🔩 4. Structural Reinforcement or Rebuild

What: Fiber-reinforced plastic (FRP) work to rebuild or reinforce the hatch opening or lip.
Why: Hull flexing caused cracking around the mount or detachment.
Techniques: Glassing in new backing plates, core replacement, tabbing reinforcement.
Seen on: Older Lagoon 380s, Leopard 40s, and DIY builds with thin laminates.

\ 5. Secondary Retention Systems

What: Installation of hatch braces, latches, locking dogs, or restraining straps.
Why: Prevent hatches from opening in a knockdown or breaking away.
Insurance-Driven: Some insurers now require secondary means of retention after losses at sea.

🔒 6. Hatch Removal & Fiberglass Over

What: Remove hatch permanently and glass in the hole.
Why: Owners who don’t plan to use it, especially if located underwater while sailing.
Often Paired With: Replacing hatch with watertight inspection plate or reinforced sole panel.
Downside: Not reversible, affects resale, reduces escape options.

🧪 7. Crack Stop and Resin Infusion

What: Drill stop holes in cracked acrylic and inject clear epoxy or methyl methacrylate.
Why: Slow progression of hairline cracks when a full replacement isn’t feasible.
Patchwork Fix: A temporary fix common during crossings or remote cruising.

🧯 8. Custom Metal Hatch Retrofits

What: Replace plastic-framed hatches with custom aluminum or stainless-steel frames with Lexan.
Why: Higher impact resistance, especially on expedition or high-latitude cats.
Downside: Expensive, heavier, may require hull mods.

⚓ 9. Emergency Temporary Repairs (Offshore Mode)

Materials Used:
- 3M VHB tape and Lexan cutouts
- Gorilla Tape and inner plywood backing
- Tarp and epoxy patches
- Compression battens or floor braces from the inside
Goal: Buy time until reaching port.
Examples: Hatch blowouts in transatlantic passages or after greenwater slams.

REPORTS

🔧 1. Goiot Escape Hatch Failures

A detached acrylic pane from a Goiot escape hatch, highlighting the failure point where the lens separates from the frame due to inadequate adhesion.
Source: Out Chasing StarsNo Frills Sailing+4Out Chasing Stars+4YACHT – Alles rund ums Segeln+4

🛠️ 2. Emergency Field Repair Using Epoxy and 5200 Adhesive

An improvised repair involving underwater epoxy and 3M 5200 adhesive to re-secure a loose hatch lens during an offshore passage.
Source: Gémeaux

🔩 3. Rutgerson Flush-Mounted Escape Hatch

A modern flush-mounted escape hatch by Rutgerson, featuring bolted acrylic glass and double rubber seals for enhanced waterproofing.
Source: Rutgerson MarinBoat Outfitters+4Rutgerson Marin+4Rutgerson Marin+4

🧪 4. Testing the Strength of an Escape Hatch

A controlled test simulating the force required to break an escape hatch from the inside, assessing its reliability in emergency situations.
Source: No Frills Sailing

⚠️ 5. Lagoon 39 Sinking Due to Hatch Failure

A Lagoon 39 catamaran that sank after its escape hatch failed, emphasizing the critical importance of hatch integrity.
Source: Yacht.deforums.sailinganarchy.com+8YACHT – Alles rund ums Segeln+8Reddit+8

NOTES

The failure will happen suddenly. The entire glass falls off. Without the brackets in that repair PDF, there is nothing except window sealant holding the escape hatch in place. The brackets won’t stop any leaks, but it will prevent the window from falling off.

However, as you correctly point out: it’s the bare minimum fix.

I would highly recommend doing impi’s fix. The contact info for ordering is somewhere in this group. Or message impi. They will share!

MANUFACTURERS REPAIR KITS
lagoon hatch repair 19009 >>

REPORTS

https://www.cruisersforum.com/forums/f136/escape-hatch-failure-194102-4.html

Helia 44 Escape Hatch Failure - Page 4 - Cruisers & Sailing Forums

Originally Posted by Buzzman Ah, OK, was not aware they were required to be openable from outside. Seems counter-intuitive unless lockable, and then you need to be sure to ‘unlock’ or ‘unlatch’ as

ESCAPE HATCH REPAIRS