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Old 21-02-2015, 13:43   #1
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Solid dodger construction –Aluminum or SS extrusion source requested

I am still designing a dodger for my Pearson P385 center cockpit. I am trying to find an extrusion that will hold 3/16” – Ľ” window material when welded into a dodger frame. Any help would be appreciate.




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Old 21-02-2015, 17:31   #2
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Re: Solid dodger construction –Aluminum or SS extrusion source requested

Google aluminum extrusion shapes


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Old 21-02-2015, 20:52   #3
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Re: Solid dodger construction –Aluminum or SS extrusion source requested

Looked a lot, have not found a simple answer, the dodger needs to tilt in 10 degrees.


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Old 21-02-2015, 21:29   #4
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Re: Solid dodger construction –Aluminum or SS extrusion source requested

try looking at rubber extrusions in some sort of h section and weld flat bar to take one side and the window material on the other or just use a flat bar or sheet and fix the window material the same as shown in boatbuilding designs with oversized holes and large washers.

most ally extrusions designed to take glass or acrylic are designed to be beaded with rubber another way is just use u shaped section with your glass and rubbers (rubbers may be substituted with sealants)
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Old 21-02-2015, 22:56   #5
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Re: Solid dodger construction –Aluminum or SS extrusion source requested

Have you done searches at www.McMaster-Carr.com & www.Grainger.com yet? Also, if you're flexible, materials wise, there's not much limit to what one can make out of; Carbon/E-Glass, Epoxy, Foam, & Wood. And via using door skins, & or cardboard, it's Real easy to mock up something in a few hours/an afternoon.

Hope it turns out well!
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Old 22-02-2015, 09:45   #6
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Re: Solid dodger construction –Aluminum or SS extrusion source requested

Neoprene tape makes good seal. I just do an overlap and seal
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Old 22-02-2015, 09:55   #7
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Re: Solid dodger construction –Aluminum or SS extrusion source requested

As I recall, forum member DELMARREY built a nice solid dodger for his boat, Ugly Duckling, and has detailed contruction documented on his blog with many photos.
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Old 22-02-2015, 10:04   #8
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Re: Solid dodger construction –Aluminum or SS extrusion source requested

Be aware that Glass can break and injure those behind it. I was involved in building some military 24 ft boats, These had an enclosure quite like a dodger with rubber mounted glass windows. During some testing in lumpy weather doing severe starts and stops a wave broke the front window out. Severely cutting the helmsman.


There is a name for that rubber seal type mounted window... it evades me right now.
I'd be tempted to put on some type of high quality semi rigid snap on dodger windows... you could then remove them in hot weather also.
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Old 22-02-2015, 15:37   #9
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Re: Solid dodger construction –Aluminum or SS extrusion source requested

I understand about glass, not using it probably will use polycarbonate. I know how to build with wood/epoxy and they look good. If I can find a couple of extrusion shapes that I can be welded into a shape that will accept the "glass" I think that would be both stronger and require less hours to do. Having 90 degree vertical windows would be easy and functional, but the wife has high visual requirements. Tilting the sides 10 degrees complicates the build.


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Old 23-02-2015, 05:35   #10
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Re: Solid dodger construction –Aluminum or SS extrusion source requested

Good point on the breaking glass, "plastic" also rolls up smaller and can be put away easier.
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Old 23-02-2015, 07:14   #11
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Re: Solid dodger construction –Aluminum or SS extrusion source requested

Tempered glass shatters into relatively safe "pebbles". Safety glass is even better. Or you could go cheap and apply a safety/security film to regular glass.
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Old 23-02-2015, 07:16   #12
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Re: Solid dodger construction –Aluminum or SS extrusion source requested

Have you thought about making your own? It's king of hard to visualize exactly what your after. If all your looking for is basically flat bar with a recess in the back to accept the glass you could do that on a table saw. Obviously not S.S. but Al. can be worked pretty easy with a carbide tipped blade.
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Old 23-02-2015, 07:23   #13
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Re: Solid dodger construction –Aluminum or SS extrusion source requested

If you are Caribbean bound the windows will need to be removable or you'll be too hot.
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Old 23-02-2015, 07:25   #14
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Re: Solid dodger construction –Aluminum or SS extrusion source requested

Lodesman, what do you mean? (referring to "safety glass" vs tempered glass) I used to own a glass shop. I know about tempered, laminated, wire glass and chem-tempered.
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Old 23-02-2015, 09:30   #15
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Re: Solid dodger construction –Aluminum or SS extrusion source requested

It was tempered glass that caused the injury.
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