Hi BlueMoon
Just recently completed cabin hatch replacement . Must be many ways to do it, more less professional or
just functional with reasonable look.
This is the way how ,,not to do it,,
Sometimes ago, I purchased the hatch from Whitworts.
Removed the old one.
Draw the new shape using a template.
Cut with hand saw strait lines, drilled the corners out.
Placed new hatch and predrilled all pilot holes.
Probably 50% was ok the rest was curved.
...old hatch had a hard wood insert, and still after 42years was ok...
...I would not use anything else...
I was too "busy" to worried about insert, and instead, I made many pieces
of hardwood different thickness, not very long.
Fill with white silicone, covered small pieces too, and push the into gaps.
Loaded the hatch overnight and next day installed all screws.
It's 2 months QLD sun and now 2 days tropical rain...all sweet.