Hard dodger Sail boat pilot house. Aluminium kit set , assembled and installed by owner

This dodger was designed as a kit set so that it could be reduced in size and crated to a remote port .

The owner assembled and with very minor trimming of bottom edge he installed on this John Pugh "Moonwind" (steel)

the upper central window opens

these pictures display the kit building process After a design as been decided on the drawings are sent out in dxf format for the parts to be cut on a CNC controlled water jet cutter..
the various bends to create joining flanges and mounting flanges are carefully done in a press brake,

 After all the parts are cut and formed the initial assembly is done and some components welded as required.

 

All components are then disassembled, degreased sanded, acid washed, then Epoxy hi build sprayed.
areas that require it are filleted with epoxy/micro balloon mix, resprayed, sanded and gloss and fleck sprayed.

Windows are then installed in the panels and allowed to cure for several days. prior to crating for transport

this same kit set method can be applied to a fiberglass dodger it is most suitable to this pilot house style.