Updating the Dodger - Modifying the Frame

Raising the existing Dodger Frame.

We're modifying the Frame in order raise the top of the Dodger so that Peggy (5'6") can see under it when stood at the Helm. It also has to be high enough that it does not obscure my (6'0") vision forwards. And it has to be low enough that the boom will not touch the top when the sail is slack, topping lift loose, Vang and main sheet taught.

Cut the Frame extender and Internal splints

2 x 12" 7/8" dia. Internal Splint Tubes
2 x 10" 1" dia. Extension Tube

I had an old 7/8" Bimini Frame that I have cut bits from for various projects over the past 8 years, and it's the right diameter for the splints. I used a 4" angle grinder with Metal cutting wheels to cut  2 pieces of 12" length. They will get inserted inside the 1" Frame tube and the Extension, then they'll get Riveted into the existing Frame. The Extension tube will probably be about 7" but I'll cut them to 10 inches and check the Boom clearance, then trim their length to fit.

From the 6' of new 1" SS tubing, cut 2 pieces of 10" length, these will become the extension of the main dodger frame, joined with the existing tube using the splint cut as mentioned above.








Remove the existing dodger canvas. 

We have done this several times, some for cleaning and restitching, and other times as part of our Hurricane preparation - Note to self: New Dodger canvas must be removable for Hurricane Prep.

This is a pic of the current Dodger, note how the leading edge of the canvas is responsible for the forwards tension, the thin line at the back of the side window provides the aft tension. Also note the Dodger Tubes are wrapped in a Boat Blanket material to stop the windows getting burnt in the South Florida Summer Sun.

Remove the Grab Rail and reconnect it to the inside of the dodger - the grab rail sets the distance between the Main (aft) and Forward Dodger tube rails.

Add the Frame extension.

Internal Splint Tubes inserted Loosly into Extension Tubes

Pretty simple, at least that's my vision on this part. Just disconnect the lower Cap end from each side of the Dodger frame, Insert the 10" length of tubing into the Cap ends, insert the 12" Internal Splint into both the new extension and the bottom of the old tube.

Reconnect the Cap end to the Deck Hinge and check the height of the Dodger for Boom clearance.

Cut down the new extension tube to get to the correct height.

Once the extension height is correct, Drill the tubes and splint for Riveting. (New Titanium Drill bits!)

Internal Splint & Extension Pop Riveted
with Stainless Steel Rivets.

To make life easier, I drilled the tubes on my home Drill Press. 
3/16" Drill with Extension in Drill vice, easy.

Pop Riveted the Splint to the Extension, solid!
The other two holes will be drilled down at the boat, I don't intend to bring the frame home just to drill 4 holes.
Finally, Attach the Stainless Steel Rail Mount Hinges to either of the Dodger side rails just below the Grab Rail attachment bolts. These will eventually be part of the connector for the new tubes that reach from the back of the new Dodger down to a new deck hinge. These tubes will replace the current piece of 1/8" cord that pulls the dodger frame aft. So the new Dodger will have a sturdy rail for crew to grab as they exit the cockpit.

Stbd side of the Dodger Frame before Modification

Close up of the Stbd Side Deck Hinge before Modifying the Frame

The Extension Internal Splint would not fit inside the
ends of the Frame. So, removed the Dodger Frame from
the Boat to take home. It hung over the back of my F150

The Outside Diameter of the Splint is just larger than the
Inside Dia of the Frame.
Hence the slot along the length of the Splint.

The Splint was still a really tight fit even with
the Slot, Here the Splint has been cut to 3.5" 

1st side Extension fitted. It's a really tight fit.
No need to rivet the Extension in place.

Considering I cut the Extension with a hand held
angle grinder, it's a pretty good fit.

Extension fitted, End Cap installed.

With the Extensions and End Caps installed on both ends of the Dodger Frame, it's time to take it back to the boat and adjust the length of the Extension with the boom in it's lowest position.

Plan is to head down to the boat on Monday to make that adjustment and to create the template for the new Dodger.

We'e hoping this goes pretty quick, but will probably take a couple of weeks. At least at this time of year (it's November 17th 2019) it's pretty cool in my Garage where I do all my sewing.

Let's see how that works out.

Making progress.