Friday, 27 March 2009

Cockpit hard dodger kit is ready

Having just fitted the laminated aft top cross beam,glued and screwed side
rails etc,I am now about to move to a painting stage.Materials and CNC work
look like costing R11,414 thats a complete kit (about U$1180),screws,epoxy roof builders jig,all plys,CNC work etc.

Windows are extras,6mm toughened glass will be what I will fit,the cost to
that and the correct sealant will be an extra.We can also pre laminate and machine to profile the top laminated cross beam,plus supply two double loop and two single loop teak grab rails,these will fit on the top and the back edges of the dodger,the size 30 Lewmar opening hatch is an option,price to these items and a full materials list will be posted later.



Note the strips of 6mm (1/4") plys cut and glass taped to the lower half of the frame works,once this is dry,removal of this jig will give us an exact copy of the frame work we can take to the boat and scribe it to a perfect fit,which will be a lot easier than taking the entire structure to the boat.


This laminated beam will stiffen the roof up,provide a very usefull hand hold and also stop driving water dripping into the cockpit.



Note the strips of 6mm (1/4") plys cut and glass taped to the lower half of the frame works,once this is dry,removal of this jig will give us an exact copy of the frame work we can take to the boat and scribe it to a perfect fit,which will be a lot easier than taking the entire structure to the boat.


Well ready but not quite ready,we continue the interesting (long) process of finding out what comes next,we are now at prime stages eleven and twelve,being the addition of the laminated beam and the fitting jig just added to the lower frame works.The laminated beam will form a part of the kit,as will the parts for the jig to form the structure to the boat,as its easy to cut and trim in the factory rather than on the boat? In my case I want this dodger to hold the weight of a person who may want to stand on its roof,I have stood on top,with the laminated beam in place but the epoxy glue still wet,its quite good,once the lamination is taken off and machined to size it will be very platform for tending the mainsail.


Our hard spray dodger can be supplied as full kits,this will include the pale tinted and toughened window glass,Dow-Corning 813 black silicone sealant to fasten them in with,plus all the wood,epoxy and required jigs to make your dodger build a success.


The fitting of a knee,makes sure this joint stays bonded,in practice the knee is smaller than it looks in this picture,if you did not want the knee (supplied) we can supply you glass tape to replace this feature,the tape is then sanded and epoxy paste faired untill it is not visible,similar to the joints on the front of the main structure.

We have now reached the stage where the roof is bonded to the lower sub frame,stage ten of development was fitting the two classic 'knees' so common in older wooden boat construction,they just made good sense in this build too.

While this build was made for a specific 43ft sailing yacht,it can be resized to suit between say a 30ft and ad a 50ft boat,even a open sailing catamarran comes to mind.

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