A Rough Game Plan for Tackling the Dodger

Like most equipment found aboard sailboats, canvas work quality is linked to the material chosen and how the parts are put together. In this case, the parts range from fabrics, zippers, clear plastic and thread to stainless steel tubing, fasteners and the mounting hardware that connects the metal framework and anchors the fabric to the boat. However, buying the best components is only part of what leads to a successful DYI dodger/Bimini build.

The pros know how to take a customer’s needs and turn them into a shape that’s in harmony with the lines of the boat. They can sew up the material so that it stretches over the supporting bows like a well-tailored suit. The first time a DIYer tackles a dodger build it becomes a design test and a measure of their sewing skills. Add in the challenge of bending 1 inch x .065 stainless steel tubing, a material that likes to kink, and one can see why weather cloths may be a better first canvas venture.

Assuming that the sewing machine is no stranger and a few Sunbrella or WeatherMax projects have been completed, the tenacious may be ready to tackle a dodger or Bimini. The double bow companionway dodger is a very useful addition to any cruising sailboat. However, tackling the project from scratch can be a daunting task, not because finishing the project is out of reach but because one may not like the results. It’s much like painting your own boat’s topsides. Getting paint on the surface is not the issue, it’s how the paint job looks and that’s a matter of where your expectations lie.

Cover craftsmanship is much the same: crooked stitching, puckered panels and odd contours stand out more to some than to others. If you expect your first efforts to duplicate what the pros provide, you’re likely to be disappointed. But those who have already developed some machine sewing skills and have a little experience making winch covers, gear bags and other canvas projects will find that dodger and Bimini work is within their ken.

The best way to further such skills is by repairing your old dodger, especially if it was a well-crafted fabrication to start with. In such cases, the fabricator got the bow-bends just right, both from an ergonomic and an aesthetic point of view. You were happy with the dodger and now it’s time to use the material and what’s left of plastic windows as patterns for your rendition of dodger 2.0.

But before you start ripping seams apart and tracing out new panels, spend some time online watching how others approach the same challenge. Also look closely at your old dodger and note whether it’s the stitching and the deterioration of the window material that’s failed and made things look so terminal. Restitching and replacing windows can be a lot easier than replacing everything. And it’s also a good way to progressively develop canvas skills.

Sunbrella and Weather Max, two of our favorite cover materials, are high strength, hydrophobic fabrics that have long since replaced the 10 ounce duck canvas favored in the early days. Key reasons for the change include increased fiber strength, durability, UV and rot resistance that add up to greater longevity. Whether you favor a DIY approach to covers and dodgers, or hire a loft to furnish your canvas work, either of the two fabrics mentioned above are the way to go. In our testing we found Sunbrella easier to sew, but WeatherMax offered a bit better longevity.

When it comes to fast-tracking canvas skills, consider signing up for some formal training. Sailrite is a good source of material, hardware, sewing machines and most importantly, detailed info for do-it-yourselfers (sailrite.com). Northcoast Marine Specialties also provides canvas training and a complete line up of tools and material ([email protected]). The talents you develop can and will be leveraged during long-term, long-distance cruising when sails or canvas work needs repairing and the closest sailmaker is hundreds of miles away.

1. DOT nickel-plated snaps will benefit from an occasional thin-coating of light grease to prevent sticking.

2. Twist-lock fittings have been favored for decades and continue to be popular among canvas makers.

3. Like snaps, push-in fittings can be fastened with one hand. Adequate reinforcement is important to prevent tearing.

4. Specialized crimping pliers, punches and hole-making tools make work much easier.

5. Holes for screw mount snap and twist fittings must be carefully sealed to keep water from entering cored decks and cabin house structures.