Dodger Panel Construction

With the drifter project completed and some minor sail repair on the Yankee jib out of the way, I got back to work on the dodger kit that dad and I had started back in the fall. Resuming the project after being away from it for so long required at least a few hours of mental preparation as I did my best to recall how we'd gone about patterning and cutting the panels months ago. Once I felt confident, I cut the remaining pieces - 2 tabling strips to reinforce the aft edge of the dodger, and a sleeve for the front bow zipper.

With that done, the instructions indicated that "now is a good time to install the windows," and that was about it - not much in the way of just how to go about it. Fortunately, I'd purchased Sailrite's "Constructing a Dodger" DVD a few years ago, so I reviewed the relevant sections and began working on designing the windows for the front panel.

Although the Sailrite DVD suggests designing the windows on the Strataglass, then adhering each one separately to the back of the fabric with basting tape, I decided that I'd be more comfortable drawing my design on the front of the fabric - with all of the necessary stitch, fold, and cut marks - then position the Strataglass on the back and cut along the lines to reveal the window material. The window design for the front panel came together nicely and allowed me to simply sew one long piece of Strataglass to the panel, then make the cuts in the fabric to reveal the windows. To ensure a smoother finish and allow a little more flexibility, I cut the window material into three separate panels once it was stitched in place. My hope is that the cuts will allow the panel to follow the contours of the deck and the frame more smoothly. The pictures below demonstrate some of this process.



Center window pattern and measurements.


Port window measurements and design.


Fabric cut away, revealing window, and edges finished.


Detail of lower radius.


Detail of corner and stitching.


Completed front panel windows.

This morning I went back to work on the top panel. I really like the look of windows in the shape of inverted triangles on either side of the dodger, so I set about to add them. I managed to take more pictures of this process since I was more comfortable with the process and wasn't so worried about wasting nearly $200 of Strataglass.

I made a few measurements of the dodger frame before beginning to ensure that the side windows were located as high as possible without being too high - I wanted them to begin just below the bend in the bows.



Side window measurements and design.


Cut Strataglass ready to begin stitching to back of fabric. Checking for size.


Securing Strataglass to fabric. First row of stitches along outside edge of window material.




Outer row of stitches completed. Strataglass secured to fabric now and ready to be exposed. (Dashed line within inner triangle represents location of grab bar)


Fabric removed, exposing Strataglass.


Cutting reliefs and folding the fabric under itself to finish the inner edge.


Ibuprofen cap worked well for forming the corner radius.


Material folded and ready for row of stitches along inner edge.


All three corners folded and ready for stitching.


Laying down inner stitches.


One window sewn in place (back side), one to go.


Both windows sewn in place and inner edge of Strataglass trimmed.

The boy made off with my ruler and pencil.



One of the hazards of spreading out my mess in the middle of the living room is that both boys are always eager to "help".