Hard dodger Pilot house style for CSY 44

Hard Dodger, Pilot house style for CSY 44
This selection of photos show a brief selection of the steps I took to build this CSY Hard dodger.
Construction is in cored glass sandwich.

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Because of the remote position of the intended boat, It was necessary for me to make a deck / combing surface copy of the actual boat and the apply this to my female mold and recopy again on to the mold.
A removable copy was made of the new mold which was then taken to the actual boat and trimed down to fit the
boat surface , fiber glass was then added to copy the actual surface of the combing and hatch cover and winch combing s

This ply and glass surface copy was then taken back to the workshop and repositioned onto the mold
I then glass up under this and onto the mold to give myself a male copy of the boat surface 

The surface copy was removed and I was left with a shiny ply mold and the exact copy of the deck and combing

inner glass laminates were applied, core was added then outer glass
laminated on note below the included top flange to receive the curved top

The top was moulded on a flat table 

one side first with its 15mm core, then curved and the inner laminateof glass added

Hard Dodger Sailboat Catalina part 3

Also see my 2007 post , bottom of page,

"Hard dodgers for cruising sailboats. this contains many pictures of Hard dodgers , some built by Me and many others by unknown builders all good for inspiration.

Hard dodger Sailboat Catalina part 2

Also see my 2007 post , bottom of page,

"Hard dodgers for cruising sailboats. this contains many pictures of Hard dodgers , some built by Me and many others by unknown builders all good for inspiration.

hard dodger Sailboat Catalina part 1

Also see my 2007 post , bottom of page,

"Hard dodgers for cruising sailboats. this contains many pictures of Hard dodgers , some built by Me and many others by unknown builders all good for inspiration.

Hard dodger pilot house Aluminium kitset dodger

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.

Hard dodger New Billabong Pilot house aluminium kitset