Building our NEW HARD DODGER - Free Range Sailing Ep 159

Introduction

In this tutorial, we will guide you through the process of building a hard dodger for your boat using PVC foam and fiberglass. A hard dodger provides protection from the elements and enhances the overall sailing experience. This step-by-step guide is designed for both novice and experienced boat builders, ensuring you have the information needed to create your own durable dodger.

Step 1: Gather Your Materials

Before starting, collect all necessary materials and tools.

Materials Needed

• PVC foam sheets
• Fiberglass cloth
• Epoxy resin
• Hardener
• Sandpaper (various grits)
• Gel coat (for finishing)
• Sealant (for waterproofing)

Tools Required

• Measuring tape
• Utility knife
• Paintbrushes (for resin application)
• Mixing cups (for epoxy)
• Respirator mask (for safety)
• Gloves

Step 2: Design Your Dodger

Creating a design is crucial for ensuring the dodger fits your boat perfectly.

Tips for Designing

• Measure the area where the dodger will be installed.
• Sketch a rough design, considering height and shape for optimal wind protection.
• Consider adding windows for visibility.

Step 3: Cut the PVC Foam

Once your design is finalized, it's time to cut the PVC foam sheets.

Cutting Instructions

• Use a utility knife to carefully cut the foam according to your design.
• Make sure edges are smooth for better adhesion with fiberglass.

Step 4: Assemble the Frame

Begin assembling the frame of the dodger using the cut PVC pieces.

Assembly Steps

• Use adhesive to bond the PVC pieces together.
• Ensure the structure is sturdy and can withstand wind pressure.
• Allow the adhesive to cure as per the manufacturer's instructions.

Step 5: Fiberglass Application

Now, apply fiberglass over the assembled frame for added strength.

Application Process

• Mix the epoxy resin and hardener according to the instructions.
• Use a paintbrush to coat the PVC frame with resin.
• Lay fiberglass cloth over the frame and apply another layer of resin on top.
• Smooth out any bubbles or wrinkles for a clean finish.

Step 6: Sanding and Finishing

After the fiberglass has cured, sand the surface to prepare for the final coat.

Sanding Tips

• Start with a coarser sandpaper and gradually move to finer grits.
• Focus on smoothing out edges and any uneven surfaces.
• Clean the dust off before applying gel coat.

Step 7: Apply Gel Coat

The gel coat provides a protective and aesthetically pleasing finish.

Gel Coat Instructions

• Mix the gel coat as per the manufacturer’s guidelines.
• Apply a even coat with a brush or roller.
• Allow it to cure completely before handling.

Step 8: Install the Dodger

Once the dodger is complete, it's time to install it on your boat.

Installation Steps

• Position the dodger in the designated area on the boat.
• Secure it using bolts or brackets, ensuring it is stable.
• Seal any gaps with waterproof sealant to prevent leaks.

Conclusion

Building a hard dodger from PVC foam and fiberglass is a rewarding project that enhances your sailing experience. By following these steps, you can create a durable and functional dodger tailored to your boat's specifications. Remember to prioritize safety during the building process and enjoy your time on the water! For further resources and inspiration, consider following Free Range Sailing on social media and checking out their additional guides.