Building a Hard Top Dodger

We have several reasons for wanting a hard top dodger. IB’s top reason: to be able to stand on it to reach the boom. My top reason: less canvas to replace, it’s so much easier to make panels of windows rather than a full canvas dodger. I’m glad IB has his own reasons, since I’m still trying to explain the finer aspects of sewing and why it’s so much harder to sew the full dodger. After all, everything is easy when someone else does it, as I’ve often commented on his projects.

Never having tackled fiberglass, our first step was getting a quote to have it made… professionally. We were quoted a figure around $4000. Somehow the summer slipped by and a decision was never made, there was not enough time left for the professional route. Decision made through indecision. In the meantime, I ran across a website of a cruiser who made his own fiberglass hardtop and he gave us some simple directions. It didn’t look so hard, so we figured we’d give it a try. Our total cost: under $800.

The plan: reinforce our existing dodger frame with four stainless supports; bend an FRP panel to fit the frame, fiberglass and paint. It was one of those super easy projects, since circumstance took me home to visit my family while my husband tackled the project.

Since we were fortunate enough to have the use of a friends backyard the entire project was completed off the boat. (Thanks Paul and Rachel!) The frame was attached to a wooden base and the FRP panel then bent to the shape of the frame and secured to the frame with fishing line. The panel was then marked and cut to size. Our choice for fiberglass materials was biaxial mat with epoxy resin. The mat was laid over the panel and cut to size. We pre-cut three pieces, planning to lay three layers the first day. The first piece was laid over the FRP panel, slathered with epoxy resin, and any bubbles were smoothed out. This process was then repeated two more times. Sort of like making baklava, but not so good to eat when it’s done. Now comes one of the most important steps that must be executed with the utmost precision: crack open a beer, drink and enjoy! Tomorrow the fiberglass process is repeated again, or in the words of our dear friend Frank, “Same f*&%#@! Thing!”

The rough edges get cut to size and sanded to a nice round edge. Now begins the faring process. Epoxy resin I mixed with glass micro bubbles, not to be confused with microbrew, that’s what you get at the end of the day. Apply the faring compound with a roller over the surface and smooth with a squeegee. In this case, the bigger, the better. Allow to dry; repeat as necessary until happy with the result. Prime, paint and it’s done. The finishing touches include the track to hold the canvas windows, and the canvas windows; my job, that’s not yet done. I have a good excuse; by the time I got back to Fort Lauderdale it was time to leave, so nothing else got done. Before I can pattern to make the canvas, the track needs to be in place. That’s IB’s job. He has a good excuse too. Before he can take the hard top off to install the track we need a day (preferably two) that the winds are not blowing 20 kts. And so the project will get completed .. mañana

The FRP Panel bent over the frame and cut to size.

Cutting the fiberglass sheets.

Applying the resin.

Sanding and faring.

The finished project, well almost.

Arch and Davits

We told them we wanted an arch and davits. The said, “We’d love to help you.” We said, “We want to keep our wind vane.” They said, “It can not be done. We put the idea aside.

At the Annapolis Boat show, we saw a display at Wells Marine, it looked just like the arch and davits we had in mind. We told them what we wanted. They said, “No problem.” They showed us pictures. We thought they looked good. The next day, they came to our boat and took measurements. Several weeks later we received drawings of the arch they would like to build us. The drawings were nothing like the pictures they showed us, and did not look like they would result in a functioning product. When we asked them about our concerns the reply we received was, tell us what you want, give us measurements and we’ll build it. Not quite the expertise we were planning to pay for. We scratched them off our list.

In a last ditch effort we tried to call stainless manufactures in Fort Lauderdale. No one returned our calls. A canvas shop recommended Alex Castro, with Ocean Tops, and gave us his number. Our attempt to call left us with no new result. Living and traveling on a boat has a way of allowing one to forget about conventional schedules and holidays, our life is scheduled around the weather. Given we tried our calls just after Christmas, we were a bit surprised when first thing after the New Year Alex returned our call. By then we wanted to leave in two weeks time and didn’t think there was anyway to get an arch built in that time frame. Alex surprised us again when he told us he could not only build what we want but he had some time available and could complete it in two weeks. He showed up that afternoon to take some measurements, evaluate the project and give us a quote. We shared our ideas, concerns, and goals; he knew just what needed to be done. The next day, he showed up with his tools and got started.

The bones of the arch were built in one afternoon on our boat. Alex worked with us, involving us in the design, position and function of the arch. We are typically do-it-yourselfers, but on this project; we did not have the knowledge, skills, experience or the time to acquire them. Being so closely involved in the construction assured us that the result would be just what we wanted.

IB did appear a bit concerned when Alex first brought out the grinder and began cutting apart the stainless rails on Passport. The point of no return, after the rails are cut apart there’s no backing out. At the end of the day we cold see what the arch would look like, and no guessing as to how it would fit. Until the day of installation, the remainder of the work would be completed back at Alex’s shop. As he packed up his tools and loaded the arch in his truck, we looked at our boat, where there used to be rails and said, “See you soon.”

We were quite impressed with the quick efficiency in which he completed the project. Within a week he returned with the arch finished and ready to do the installation. For the arch and rails around the cockpit to flow together as one unit, the cockpit rails were completely replaced. The end result is not just a strong functional arch, davits to lift and carry our dingy, or a rope swing, but a work of art.

The back of the boat before we started.

Another view of the back before the destruction.

IB's expression when the grinder touched the first rail.

That would be our boat being torn apart.

Deciding how to attach the rails.

Boat with no rails.

Unloading the arch.

Welding into place.

The finished product.

Freezing in Florida

I realize that all you northerners that are covered in snow are not at all sympathetic with our sub 60's temperatures, but it's cold down here! I feel that after our great effort, and slow travel by boat to southern Florida we deserve to at least put away the sweaters and down. But oh well, perhaps next week.

We have arrived

at our "final" US destination, Fort Lauderdale (that is a very loose final, since I'm not so sure that any our decisions are really final until they are executed). We actually managed to leave Vero Beach on December 27th (Velcro Beach, and yes we stayed at least a week longer than planned). Our stay at Vero was great, we met some wonderful friends that we hope to see again down the way. The trip to Lauderdale was easy and uneventful, we had great sailing for half the trip before we

had to turn on the motor as the wind died. Early monday morning we arrived at Port Everglades inlet and

headed up the New River to our home, for now. We are very grateful to John and Susan for letting us tie up at their house and enjoy this beautiful river. We even had a welcoming party come out to greet us.

Since we found ourselves in Fort Lauderdale over New Years Eve we decided to take the dingy out and see what the town had to offer on this celebratory evening. The evening began with a very pleasant and warm (the last warm day we had for quite some time) boat ride down the New River. Along the way there were many decorated houses and yards full of lights for Christmas. We arrived downtown earl

y in the evening to enjoy dinner out before the night life fully enveloped the streets. As we sat at our outdoor table on the street, we were able to watch as the streets slowly filled with people and the bands began to play. At midnight we witnessed a balldrop and fireworks.

Some of the night life.

When pine trees are not available, decorate palms for Christmas.