Building a solid dodger

[duckpond49]

A coupla seasons ago I replaced my canvas Bimini top with a rigid top on the existing SS frame. Like it way more than the previous canvas approach. I'm making plans to use what I learned from that to rebuild my dodger with a similar hard top on the existing SS frame and make new vinyl windows wrapping around the lower part.
I didn't want a lot of weight on the old canvas Bimini frame so I used Aqua-Plas 1 ULTRA PVC for the rigid Bimini top. It weighs 45% less than Starboard and cost half as much. (It is, however, not as tough -you can mar it with a sharp edge) I made a wooden form to bend the PVC board to the proper curve after heating in a steam box. Might try Starboard for the dodger since it won't be as expensive and it's stiffer so I can climb on it some.

[Allied39]

Okay, so I am reading a lot of..."I cant be bothered" "it's easier to" "I dont have the patience to" etc etc etc.

And I understand that there's a lot of folks that don't have the skill , drive, ability, patience or, to be honest need, to do what I do.

Iam just posting the pics of what I did to give the OP and idea of whats possible if desired.

Sorry for the clarity of the pics, she's on the ground gettin some loving, so not as neat and orderly as she should be

Oh, and I cant for the life of me work out how to rotate the pics.....I am way better with fiberglass than posting pics

[drivn2ironman]

I'm currently looking at building a hard dodger also, but was going to design the roof top as a rain catcher system with Y inside. first you let drain on deck to remove all dirt/salt, etc... and when clean, send the rain water into your water tank to refill.

[QUOTE=anacapaisland42;2874615]I've built one on our boat (Challenger 32).
The single most important item is that the forward roof line must follow the shape of the forward cabin top and the aft line follow the profile of the stern.
Also make sure the curtains spill water/rain/run off OUTSIDE the cockpit

Then it will look good.
Bill

Originally Posted by nzmal

Has anyone been through the process of replacing their canvas dodgers with a solid one?

[B_Wieberdink]

I have a Contest 31 and build a hardtop dodger myself out of foam and epoxy. The windows are Lexan in home made profiles of carbon fibre /epoxy.
It is very strong, you can stand on it.
I made it some 10 cm lower than the original dodger.


Bert

[swdreams88]

Mal, last year we were faced with the same decision after having two previous dodgers made from Sunbrella. The tropical sun is just too strong for these to last. If you stay with fabric use a dark color. This seems to help with life span. However, thecother issue we had was heat (sun) radiating through onto our heads. I use the existing structure and made a hard top with rigid foam inclosed. Nice! No heat, not too heavy, removable. A few years ago we did a bimini hard top. Very happy to be away from canvas. If you would like to skype and have a chat give us an email.

[Steve Whelan]

Can you just glass over the original (in place)?

[Allied39]

Originally Posted by Steve Whelan

Can you just glass over the original (in place)?

No, not really.

Actually in the next week or two I am taking the bimini off my boat and replacing the canvas with fiberglass.

As I have stated before I am a epoxy resin guy, I don't bother with anything else. Thats just me.

My plan is to take the bimini off, bring it home , knock up a mold to take the shape of the existing frame, lay up some glass.

I am hoping to sail up to NY to pluck my rig and back so I figure what I will do is knock up the basic unit but not finish paint, see how I like it or If I want any changes on the sail . When I get back I will finnish it off or make the changes I want then finnish it.

I might take a few pics and post the process if I have the motivation.

[Yellowbay]

Follow the boat had one built with rain cater and routing for lights etc. I’m thailand and Atticus sailing built one by themselves in Mexico. Check them out

[chouliha]

We did a hard too using dyvincel. We took a few pics of the build which you can find here https://www.jacarandajourney.com/other-good-stuff. #9 in the list

Good luck

Chuck

[Allan M]

Hi Mal,

I'm a liveaboard in Nelson Marina, Berth G27 if you want to have a look at my recently completed project - almost identical situation to yours.

Cheers
Allan

[Allan M]

Hi Mal,

More photos of my recently completed dodger.

Cheers
Allan

[jsanton]

I have the same project in mind.

Recently, I made a bimini out of 1/4” starboard and mounted solar panels on it. So far, I love it. If in a year, I still love the starboard bimini, I plan to build a starboard dodger.

For the dodger, I’m thinking the roof will be 1/4” starboard resting on the existing ss frame. Then bolted to the frame with u-bolts. The sides will be eisenglass or polycarb in fabric frames with awning track on the top edge tying it to the hardtop. I don’t want weight up there so will stick with 1/4” starboard. The curve of the ss frame that was put there to keep the fabric taught does a nice job of stiffening the thin starboard.

For me, it’s important that the center window is openable for hot anchorages.

A huge advantage of starboard over fabric is protection from the heat from the sun. Starboard is much cooler sitting in the shade.

Another advantage of starboard is nothing sticks to it- epoxy doesn’t, and neither does bird caca.

[nzmal]

Originally Posted by Allan M

Hi Mal,

I'm a liveaboard in Nelson Marina, Berth G27 if you want to have a look at my recently completed project - almost identical situation to yours.

Cheers
Allan

Thanks Allan
I'll definitely look you up when in Nelson. We just got home to Chch.
What was approx cost of project?

[Allan M]

Hi Mal,

I built it myself so no labour cost! I’m guessing NZ $1200 for materials and fittings. My neighbour said he had a similar job quoted at $18K – he went with canvas on a s/steel tube frame!! It took me about 3 months of fairly solid weekend and evening work so it wasn’t a very efficient process. Being built in situ you have to allow for weather interruptions and drying times for glue, fiberglass and paint systems. I would think there would be a month of full time work in it for someone with appropriate skills. I’m not sure what hourly rate a boat builder would charge but I suspect you would be looking at NZ $10 – 12k. I have no idea what a similar structure in moulded fiberglass would cost.

Cheers for now
Allan

[nzmal]

Originally Posted by Allan M

Hi Mal,

I built it myself so no labour cost! I’m guessing NZ $1200 for materials and fittings. My neighbour said he had a similar job quoted at $18K – he went with canvas on a s/steel tube frame!! It took me about 3 months of fairly solid weekend and evening work so it wasn’t a very efficient process. Being built in situ you have to allow for weather interruptions and drying times for glue, fiberglass and paint systems. I would think there would be a month of full time work in it for someone with appropriate skills. I’m not sure what hourly rate a boat builder would charge but I suspect you would be looking at NZ $10 – 12k. I have no idea what a similar structure in moulded fiberglass would cost.

Cheers for now
Allan

Thanks Allan.
I'm handy enough to build one once I have a plan in my mind. I'd like to figure a way to mock one up in Christchurch and transport it up to the boat in Havelock before settling on shape. I need to start by approximating a shape though and this needs to be done on the boat..I'm not sure how I'll do this... it would be a lot of clay or closed cell foam lol. Maybe wire and mesh... If my existing dodger was in worse repair I'd be tempted to just wet it out with resin and use it as the foundation for a mould... then trailer it home to the workshop. It would be a tough project while living aboard and without a workshop. Well done!