Updating the Dodger - Refining the design

Refining the Design

Anyone that has watched the Sailrite video knows that it's normal to make minor adjustments to the design during construction. Well, that's true here for me too!

After cleaning up the Top template and the Front template, we discussed the cockpit venting aspect of the design. A bit of explanation is due here.

When we are at Anchor, most of the time, the boat will point into wind, unless water current is more powerful and then it's a guess which way we'll be pointing. Most of the year here in South Florida, and certainly in the Bahamas, it gets pretty warm when sat in the cockpit if the front window is fully closed. Our old Dodger design did not have a designed vent option, so we typically would unzip each side of the front window and fold it back leaving about a foot of vent on either side.

Dodger Old Design with Front Window folded open on each side.

The Front Window Zippers each began in the middle of the top.

We discussed the options to improve on that method of venting the Cockpit, one included adding a Smile, a U shaped, zippered opening in the middle of the front window. That seemed like a better solution. After waking early the next day, it occurred to me that all we needed to do was install the Zippers from the lower edge of the window to the top center. That would allow us to unzip from the top middle and fold down a portion of the window. Thinking through the concept, it would also improve visibility if the window was fogged up, with the added benefit that the opening would be the full width of the window.

Dodger New Design with Front Window folded down (open) from the top

We took the templates back down to the boat today, I was curious whether I could adjust the two back support bars to be at similar angles to each other. Turns out that was no hassle and worked out great.

With the Dodger frame set up, I held the Side Window Templates in place with some Pony clamps and adjusted the lines on the template. My concerns was that the lower edges of the side window templates were a little off line. They were! But that's why it's ok to remeasure everything, and make adjustments, just like they do in the Sailrite Video.

The initial template markings took nearly 3 hours to complete, add another hour today. In addition, today's review of the templates has given me some concern that the front window template might be a tad off and that it's not easy to establish a really good template markup due to the lower front edge of the front panel strips is really difficult to establish. My solution is to make up the Top Panel with the attached front window surround and side strips, the two side panels and take them all down to the boat for fitting. At that time I'll make a template just for the Front window panel, it should be a lot easier because the Side strips will be held in place.

One other thing I considered was adding 2 more tubes to the Dodger Frame. Whenever I'm on deck, heading back to the Cockpit, I'm always concerned that I may put some weight on the canvas Strip that holds the Front Window in place. By adding the two Forward Safety Grab rails, one on either side of the Dodger frame, that would give anyone going from the side decks back towards the cockpit something to grab before getting to the Dodger grab rail. Safety is a big factor for me and Peggy always supports safety upgrades. The two grab rails would be about 45" long, going from the existing Dodger grab rail, forwards and down to just aft of the cabin top wooden grab rails.

Dodger re-design including Forward Safety Grab Rails

Ok, now it's time to do some canvas work. A quick markup of the reviewed templates for the side panels and then out with the Hot Knife.

Well worth the trip down to the boat today! I also had the chance to clean off some of the glue residue from the shipping tape that was stuck to the Dodger Frame. My personal favorite goo remover is Goo Gone.

A quick few spritz' on the metal tube surface and spread around with my fingers, leave it for a few minutes, about 5 is normally plenty. Then rub off the goo with a rag. If there's a lot of goo to remove, a second treatment might be needed. 

It easily took the Glue goo left by the Shipping tape on the Dodger Metal Tubes and the on the Fiberglass Surfaces. Less than 15 minutes to clean it all up.

Now I'm Off to do some canvas.