Hunter 40.5 Hard Dodger

[Frank P]

For any of you interested in hard dodgers, here are some photos of one I just completed for my 40.5. I built this with the following:
- Divinycell foam core
- 1208 biaxial and 1.5 oz mat, polyester resin
- White/red LED lights with dimmer
- Stamoid canvas sides with Makrolon glass.
Frank

 

[DayDreamer41]

Looks great @Frank P a project which is on my list as ....... some day. How did you support the aft section of the hard top? I see the forward support posts.

 

[jssailem]

Looks great Frank. An interesting project.

 

[Frank P]

The aft support and top are one integral piece (Divinycell/glass). I was originally only going to make the top similar to the Catalina hardtop with an all stainless support however I was getting quotes from $2,800 to $3,000! One of these quotes was from the company that make the supports for Catalina. I think I paid under $300 for the two individual supports and that was with me mocking them up to get the angles so the fabricator would not need to come to the boat.

I have not added all the cost for making this, I don't think I want to....I made everything except the stainless supports

Frank

 

[Rick D]

Frank, it looks like you're doing what I did all last year...projects! When I saw this title, I thought "oh no, another ugly DYI add on". I am so glad I was wrong; it looks GREAT. Congratulations. Actually, it resembles the factory ones on Catalinas to my eye. Nice job!

 

[Bob J.]

That came out looking awesome, seriously awesome.

 

[Joe]

Nice.... it appears to be supported with single poles on each side, like a "T-top" with canvas side curtains. Looks like it will do the job.... and it's pretty.

 

[Rich Stidger]

Frank P- Are you taking orders?

 

[Frank P]

Ha Ha....Hey Rich, my wife said no more projects!

Frank

 

[Franklin]

What do you think it weights?

 

[Frank P]

I'm not sure, my son and I easily carried from the trailer to the boat at the slip. He and I got it from the dock to deck of the boat without too much hassle. I would WAG 80 lbs max

 

[SailormanDan]

@Frank P - why did you use the stainless for the front supports and not fiberglass like the rear? The quality of the work is so clean, I was thinking the front was fiberglass, until I saw the other photos.

 

[Frank P]

Dan
I didn't want the view obstruction of the mullions as they would have been fairly large to get the strength and stiffness needed for front supports.

 

[SailormanDan]

Thanks Frank, I've never made anything out of fiberglass, sounds like if I ever do, I'll really need to do some research.
I love the makrolon and am looking at including that in my projects.

 

[CaptKimble]

I'd like to add that I have seen this project in person and am totally blown away. A real professional job and amazing installation. Anytime you want to make one for me Frank I'll let you...(signed...Tom Sawyer) LOL*

 

[Frank P]

SailormanDan
Photos of the fabrication are in my Flicker files. Be ready for LOTS OF SANDING!
https://www.flickr.com/photos/18524873@N04/albums
Frank

 

[SailormanDan]

Thanks for posting the link to the photos, I had to chuckle at the "bug-eyed monster" that popped up on the first page.
I was not aware of the effort involved, I am not worthy!

 

[pateco]

SailormanDan
Photos of the fabrication are in my Flicker files. Be ready for LOTS OF SANDING!
https://www.flickr.com/photos/18524873@N04/albums
Frank

I love the pictures of the project. How many hours do you estimate it took from concept to completion?

 

[Frank P]

I would guess close to 300 hrs between research, sourcing material and labor

 

[Alan Johnson]

Frank
Hope you can add some detail. What thickness or gauge is the Makron and was it sewn of the sailrite.

Alan J C400 Skol