DIY dodger

[chp]

Originally Posted by Katapult Mike

For me, the appeal of the Lexan dodger in the link is ease of construction. One material, bend it onto the frames, paint and you are done. On further refliction though, I don't like the painting of the Lexan. I expect the paint is liable to scraping and chipping, and the end result is too shiny for my taste. The builder did get a good shape going though. As others have noted, most hard dodgers tend to be pretty squared off and not rounded like cloth dodgers. And a lot of people only do a hard top, meaning you still have to deal with sewing the windows in front and sides, or pay someone to do it.

As for builindg one out of fiberglass, whether laid up over ply or foam, sure, you can get a great result from that. But all the write-ups I have seen say that it is a LOT of work to get a good cosmetic result. A lot of filling, fairing and sanding. The chipping and scraping off the paint on the Lexan was also one of my thoughts.

I plan to [attept to] build one using FRP panels like HomeDepot sells for the top, and Lexan for the windows. I haven't decided whether to do the windows in one continous sheet like the guy in the link the OP posted did, or with separate windows and frames like I have seen some others do online. My goals are to avoid sewing, which I have no experience of, and avoid lots of filling, fairing, and sanding fiberglass.

Problem I see with the FRP is that it is stated for interior use only. I don't know if you could use it for the shape and then glass over it to protect it from I'm assuming UV rays. I know it's very flexable and would be very easy to shape and work with.
The paint chipping and scraping off was also one of my concerns.

[coopec43]

Originally Posted by chp

Problem I see with the FRP is that it is stated for interior use only. I don't know if you could use it for the shape and then glass over it to protect it from I'm assuming UV rays. I know it's very flexable and would be very easy to shape and work with.
The paint chipping and scraping off was also one of my concerns.

Obviously FRP has a different meaning in the US?
(In Australia "FRP" stands for "Fiberglass Reinforced Plastic")

Polyester resins can be used to make a variety of products, including: Fiberglass reinforced plastics (FRP) - commonly used in boat building, tanks, pipes, and other structures. Automotive parts - such as body panels, spoilers, and other exterior parts.

https://www.fibreglast.com/category/Polyester_Resins

[Katapult Mike]

FRP = fiberglass reinforced panel. They are very thin pre-made fiberglass sheets builders use to skin over walls in kitchens and bathrooms.

[Katapult Mike]

Originally Posted by Katapult Mike

FRP = fiberglass reinforced panel. They are very thin pre-made fiberglass sheets builders use to skin over walls in kitchens and bathrooms.

Like these from HomeDepot: http://www.homedepot.com/p/Glasliner...9600/100389836

No UV protection, for sure they would need to be painted.

[coopec43]

Originally Posted by Katapult Mike

Like these from HomeDepot: http://www.homedepot.com/p/Glasliner...9600/100389836

No UV protection, for sure they would need to be painted.

Well that goes for any fiberglass product as well. It has to be gelcoated or painted to protect it from UV,



Why would you buy a panel from Home Depot? (I don't think that is very wise at all)


What's wrong with this?

[gonesail]

aluminum .. not SS tubes? you already lost me there.

[Katapult Mike]

Originally Posted by coopec43

Well that goes for any fiberglass product as well. It has to be gelcoated or painted to protect it from UV,



Why would you buy a panel from Home Depot? (I don't think that is very wise at all)


What's wrong with this?

Nothing wrong with that result. It is the process to get to it. From the article written by that guy, two excerpts:

All corners and gaps need to be filled and rounded. No fancy fillers are necessary here—Bondo, West System fillers, heck, even epoxy with unscented baby powder or talcum from your local pharmacy will work. Good sanding and fairing afterward is going to make the dodger look much more aesthetically pleasing.

That said, it was far and away the most underestimated project I have undertaken in terms of time needed, so be forewarned: this project is one that is best conquered during the off season, when you have some time. If, however, you are a serious cruiser and prefer comfort and protection from the elements over the notion of the wind in your hair then this is a project for you.

http://www.sailmagazine.com/diy/how-...ard-top-dodger

Bottom line, it's a lot of work, even if "you know what you are doing" (which I don't).

Compare that to this project:

The dodger top was relatively quick and easy to *fabricate. I made a template with door skin (thin, flexible wood veneer), cut the first pieces from an FRP panel with a jigsaw, and then cut mirror-image pieces to glue on top. Clamping the bottom pieces onto the dodger frame, I then spread on the adhesive and clamped on the top laminate. These FRP panels are quite flexible, and easily made the pronounced bend at the outboard ends.

http://www.cruisingworld.com/homemade-hardtop/

[coopec43]

Originally Posted by Katapult Mike

Nothing wrong with that result. It is the process to get to it. From the article written by that guy, two excerpts:

All corners and gaps need to be filled and rounded. No fancy fillers are necessary here—Bondo, West System fillers, heck, even epoxy with unscented baby powder or talcum from your local pharmacy will work. Good sanding and fairing afterward is going to make the dodger look much more aesthetically pleasing.

That said, it was far and away the most underestimated project I have undertaken in terms of time needed, so be forewarned: this project is one that is best conquered during the off season, when you have some time. If, however, you are a serious cruiser and prefer comfort and protection from the elements over the notion of the wind in your hair then this is a project for you.

http://www.sailmagazine.com/diy/how-...ard-top-dodger

Bottom line, it's a lot of work, even if "you know what you are doing" (which I don't).

/

For someone who knows fiberglass it wouldn't be a difficult job.


"All corners and gaps need to be filled and rounded. No fancy fillers are necessary here—Bondo, West System fillers, heck, even epox....."

So if you use Lexan (or some FRP panels from Home Depot) that is not necessary? No they don't fall together!

The bottom line is if you have never constructed anything before you will find it a daunting task no matter what material you use..

Try building this.

[Katapult Mike]

Originally Posted by coopec43

Try building this.

No thanks. You guys with the skills can keep building the hard stuff, I will keep looking for the easy way!

[coopec43]

Originally Posted by Katapult Mike

No thanks. You guys with the skills can keep building the hard stuff, I will keep looking for the easy way!

If I had to build a canvas dodger I wouldn't know where to start. But to others it would be a cinch .

[jsanton]

I built mine from starboard. Nothing sticks to it. Including bird poo. And it’s cool shade.
Lots of fitting

[newhaul]

Originally Posted by s/v Jedi

You wish… you will need two coats of primer and at least three top coats before you get anywhere near the same level as proper dodger material.

Just glue sunbrella to the top and done.