Bimini / Dodger / Etc...

click to see full size image

 

Photos of the dodger/bimini project starting January 2009

January 2009

Two truck toppers arrive for their conversion.

Removing windows and preparing to trim off the sides.

The second one trimmed down to a more manageable size.

The pattern for the leading edge of the dodger cut out of some boxes I had laying around the garage.

The pattern taped to the smaller of the two tops.

10 January 2009

The pattern is drawn out and the rough cutting starts

The rough cutting complete.

The lay out is complete, now it's time to put on the respirator for the dusty part... Sanding off everything outside the tape.

11 January 2009

Trimed up to its final shape. Now I've got to start with the epoxy and fiberglass matting. Need to even up the underside and get the core sealed back up.

24 January 2009

It's 70 degrees out, finally warm enough to do some fiber glass work to seal up the core.

Opened up.

First coat of epoxy and some fiberglass backing, and as usual fiberglass hates turning corners. Time for method two and I'll have to go get some weaved fiberglass blankets, they turn corners, but cost about $30 vs. the chopped blankets which cost only $5.

So... method #2 seal the corner with masking tape, drill holes and inject straight epoxy into the interior.

1 hour later you have a solid surface that will need some shaping, but will be ready to cover with the blanket glass when I get it.

16 February 2009

The leading edge glassed up and ready for some sanding.

Back to Projects

 I started this project in 2006, got as far finishing the frame, stuck in the garage and pretty much waited for it to finish its self...  Doesn't look like this strategy is working so I've finally pulled it out and decided to move forward with it.

2006 - Starting the never ending project...  Most of which will have to be rethought now that I'm going in a different direction with this.

Thank you to the anonymous donor down at the marina for two of these frames, and proving once again; one man's garbage is another man's treasure. It gave me a starting point and saved me the cost of ordering a bunch of stainless steel tubing and all the fittings.  I've been pricing tubing and a hydraulic tubing bender on the internet the last month or so, this is a welcome free-be.

I took some measurements on the boat and sketched out a rough drawing of where I'm going with this project.  Unfortunately, having never done this before, I'm making it up as I go.  I'm starting with where I want the aft end to be and I'm going to work forward one loop at a time until it ties into the dodger frame.  The initial measurements I took were the distance between the hand rails where I plan to attach it.  That done I measured from those points aft to the hand rail's furthest point aft, where I want the top to terminate, right behind the driver.  The other measurement I took was from a few inches over my head to the attachment point.  That's how high it's going to be, and the good news on that measurement; it is below the boom, so I don't have to worry about it interfering with the movement of the boom.  Now if only I could remember all that geometry crap I slept through in high school and college.

I started by cutting 10" out of the middle of one of the used frames and then rejoined them, using solid stainless stock that fit snugly into the interior of the tubing.  I then drilled,  tapped, and installed stainless screws with plenty of Loc-tite.  You can see the frame in the second picture back in one piece but 10 inches more narrow than the original. (also in the picture)

I then took the frame to the boat and hung a plumb line from the center of the aft arch and moved it around until it was 31" above the existing life rail and even with the aft hand rail.  Marked it, and cut it to length.  I re-installed the end fittings and attached it to the existing hand rail. 

Another trip to the boat, some more measurements, cutting, joining, and the forward loop is done.  All the fittings have been drilled tapped and attached.  The frame is ready for installation on the boat.  Now I need to reinstall the dodger frame and tie the two together.

January 2009 - Back to work on the never ending project:

Well, it's been another year still no bimini or dodger, the plans have changed.  The spring is coming and I really want some shade on the boat.

I was surfing around some sailing web sites and came across a company that sells hard dodgers and biminis.   But of course, anything specially built for a boat is specially priced for a sucker.  So I started thinking, how can I do this on the cheap but still have a good looking product?

I started studying different methods of laying up fiberglass, considered building a mold, or creating a plywood core and covering it with fiberglass.  Having done a little fiberglass work, I wasn't really all that keen on the idea of doing a lot of fiberglass work.  Then after pricing the glass blankets and the resin required to build an entire unit, the price started inching up pretty quickly.

Then one day I was driving past a Ford dealership and noticed a fiber glass truck topper laying in the garbage and thought, I might be able to do a little modification work on a big flat sheet of fiberglass like that.  The trick will be finishing it up and not have it look like I've suspended a truck topper over the back of my boat.  I'm confident I can pull it off.

A few measurements of some truck beds and an ad on Craig's List; I had two toppers laying around the house just waiting for my attention.

So with that said.... the Dodger and Bimini top for the boat is back underway after a year of stagnation.

More later as the project progresses

Back to Projects