Hard Top DIY Bimini & Dodger Materials?

[sailingharry]

Originally Posted by capn_billl

I made a hard top for a previous boat out of 1/4" poly plastic. Available in several basic colors including tan, and easily formed with a heat gun.

This is exactly along the lines of what I was saying about a few layers of fiberglass. But perhaps even easier!

What was your source for the material? Or a more specific description of it? I think that this could really be the way to go.

One potential limitation is size, our current Bimini is about 5 by 9 which precludes pretty much everything from the home center unless you join sheets together.

[jsanton]

I made mine from 1/4” starboard. It’s so slick, nothing sticks to it- epoxy or bird poo. Always stays clean. Fitting the pieces is a big project. Figure 2 weeks or more. Mine is in pieces that interlock. Stows easily. Comes down quick. I plan to build a wiki for how to.

[sailingharry]

Originally Posted by jsanton

I made mine from 1/4” starboard. It’s so slick, nothing sticks to it- epoxy or bird poo. Always stays clean. Fitting the pieces is a big project. Figure 2 weeks or more. Mine is in pieces that interlock. Stows easily. Comes down quick. I plan to build a wiki for how to.

For my installation, Starboard presents interesting challenges. Since I need 5 ft x 9 ft, and Starboard comes 4x8, it would take four pieces stitched together in some fashion. If there was a way to do that nicely, I agree that it is probably the best material for the job!

I'm really interested in how you got the pieces to interlock.

[jsanton]

Where I purchase it, it’s actually larger than 4x8. Eplastics.com

My dodger roof is the single largest piece. My bimini roof is larger, it is made of 3 pieces- each fitted with a solar panel, i created a slot with starboard, so they slide into each other. I intentionally wanted these pieces small in order to make it removable and stowable.

I left the dodger roof large as I don’t see the need to remove in a storm. The dodger sides are separate panels and easily removable.

[jsanton]

A pic…

[Kd9truck]

Originally Posted by jsanton

A pic…

Nice work! I could not use the link but did get to the site with a different search.
Which material did you use?

[sailingchiro]

I was too lazy to build a fiberglass hardtop and used Starlite. It is lighter than Starboard and comes in 5' x 8'. My top is 11' x 8'. I took two pieces with acryllic windows in the middle of them so I could see my sails. It was easy to trim, router, bolt, screw, etc. Alot less time and effort. Still looks great after 5 years. I can walk on it. I mounted my solar panels to it. Had the project finished in a couple of days. Not weeks. I used 3/4". If you don't need to walk on it, 1/2" would do fine, I am thinking. Probably alittle heavier than you would like, but I like the simplicity of it and the lack of work involved.

[sailingchiro]

Originally Posted by sailingharry

This is exactly along the lines of what I was saying about a few layers of fiberglass. But perhaps even easier!

What was your source for the material? Or a more specific description of it? I think that this could really be the way to go.

One potential limitation is size, our current Bimini is about 5 by 9 which precludes pretty much everything from the home center unless you join sheets together.

Starlite is 5' x 8' if that helps. I put a 1' roll of acryllic windows inorder to see my sails. My top is 11' x 8'. I don't think you will regret how simple it is to work with. I knew if I made a fiberglass top, I would only see all my imperfections.

[jsanton]

I used 1/4”x54”x96” starboard. I think it’s King Starboard. Seaboard is the same thing- just a different brand.
E plastics is in San Diego and known here as Ridout plastics.

[waterant]

have you considered using solid solar panels as the structural top for the new doger/bimini instead of building a top and attaching flexible panels to it?

on my previous boat, I used 2 large 200w panels as the top and built a new frame for them using 1.5" architectural rail 316 SS tubing with various SS fittings widely available.

Ended up with light frame and solid solar panels which are much less expensive, more reliable, and more efficient than flexible panels. no extra material which adds a lot of weight. they would be easy to remove (each was fixed with 4 bolts to the new frame).

[pem725]

Terry et al,

Not sure if you have already started (or finished) your hard dodger but we own and B473 (2005) and plan to make one. Would love to compare notes.