I know there are other posts on this topic but I wanted one that doesn't debate if there is a problem with the O ring design and instead contains solutions forum readers have tried that work and don't work with specifics. I have a pair of first generation Outfitters that have both leaked excessively in rougher water since new while hardly leaking a drop on calm lakes and waterways. By excessive I mean a quart or more per hour. I was able to identify the source of the leaks early on by taping strips of paper towels in various places and confirming water was seeping past the hatches (especially the rear position crotch hatch and the stern hatch) but did not know why. Just figured "they all do that" and so we drained them anytime we beached.
Other posts identified/confirmed the root cause of the leaks as the O rings "rolling" so that rather than a corner surface facing out, a flat surface faces out and does not stick out as far, forming a poor seal.
For reference on proper O Ring positioning please see US Patent US8453589B2 Hatch With Cover for Boats filed by Hobie Cat Company.
http://www.google.com/patents/US8453589CORRECT O RING POSITIONING
LEAKY O RING POSITIONING
As others have reported, correcting the positionng usually only works until the next time the hatch is closed and, in fact, these photos were taken a few seconds apart. I reseated the O ring properly, took the first picture, closed the hatch, opened the hatch and took the second picture.
Possible solutions using Hobie O rings:
1. Glue. I have 6 new O rings but want them to seal properly. I am looking for a decent waterproof glue such as E6000 or Goop that will adhere rubber to plastic. I recall at least one poster used glue and would like more details.
2. Grease. Several posters used various grease-like substances to improve the seal. Per Matt's recommendation, use only silicon based lubricant as petroleum based greases can damage the O Ring material or cause stretching. (See links A5, B1.)
3. Teflon Pipe Thread Tape. At least one forum user has had success with white Teflon piping tape to reduce leaks. (See link A1.)
Other solutions:
1. Different O Rings. One poster found an alternate O ring with circular cross section that worked and the following link provides sources and part number for a replacement (non OEM) O Ring with round cross section. (See Link B5)
What else have you done that did or didn't work?
Interesting posts in these forums related to hatch issues:
A1 Leaking Twist-n-Seal Hatch and Teflon Tape
http://www.hobiecat.com/forums/viewtopic.php?f=11&t=43211A2 alternate twist n seal hatch gasket
https://www.hobiecat.com/forums/viewtopic.php?f=11&t=48057&p=213289A3 Old Problem but not Solved, Leaking T&S Hatches
https://www.hobiecat.com/forums/viewtopic.php?f=75&t=32772A4 TnS Cover O Ring
https://www.hobiecat.com/forums/viewtopic.php?f=71&t=20898A5 Which Silicone Grease?
https://www.hobiecat.com/forums/viewtopic.php?f=75&t=11630Other interesting links regarding hatch issues:
B1: Leaking Hobie Adventure caused by Twist-n-Seal Hatch?
http://www.northwestkayakanglers.com/index.php?topic=6384.0B2: Hobie Twist & Stow Hatch Leaking
http://www.kfdu.com.au/forum/viewtopic.php?f=7&t=42297B3: Hobie Hatch Questions
http://www.norcalkayakanglers.com/index.php?topic=18846.0B4: Hobie Hatches, Poor Sealing
http://www.vyak.net/forum/viewtopic.php?f=11&t=14710B5: Hobie Hatch O-Ring Replacements
http://www.northwestkayakanglers.com/index.php?topic=13269.0Peter