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
No comments:
Post a Comment