This is not an easy project.
It is well beyond the "small boat project" range. And yet, it is so well executed that I couldn't resist drawing your attention to it. Mike of
s/v Chalice has tackled the creation of a hard dodger. And he has done it in yeoman fashion. Pay particular attention to the tools and tooling that he creates in order to do the actual project work:
- A rib glue-up table
- A buck for gluing up the roof panel
- An adjustable jig to support the roof panel in place in the cockpit while supports are created
- A rolling gantry (!)
Given Mike's proclivities, I'm sure that this is not an exhaustive list. Tho creation of the tooling and tools took perhaps as much time as the project itself, the result shows that this time was well-invested.
Yeoman work indeed.
What follows is a combination of two of Mike's posts (I wish there was a third showing the completed dodger).
So here we go. This was spread over about a year. First I made the actual top piece, then the bottom rail was made right on the boat. Then I built the gantry crane to set the top piece up there and join the two together.
I started with a table to make the mahogany ribs that are internal to the top.
Made with OSB, filled with thickened epoxy, sanded, then clear coated with epoxy again to give a nice smooth surface then waxed about 8 times so the glue would not stick to the form.
Next a large form was made that matched the same curve as the ribs. I did not take pics of that part. I have a few of the actual glue up of the top piece.
There is a layer of 1/4" luan on top and bottom. Mahogany ribs with 1/2"foam panel between them with solid Mahogany about a foot around the edges.
I used plastic nails to nail the first layer to the form. This allowed easy removal and sanding. I used a cheap Harbor Freight 18Ga. nail gun. Worked great and saved about $300 from buying a Italian gun made for them.
Later I cut it to shape and glassed it top and bottom.
So now we have the top up on the boat. I built an adjustable jig to hold it so I could get the right height and location. Here are some pics with the process of fitting the top to the bottom rail I had made earlier.
By the way, this was the most difficult part.
Starting to look good. I think.
Looking lean and mean.
Dirty boat.
Ok now we have it together (barely). So let's lift it off and to the ground.
On the work horses for final assembly and finishing.
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