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[email protected] koosvander@gmail.com is offline
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First recorded activity by BoatBanter: Aug 2007
Posts: 14
Default Forming rounded corners with Fiberglass and ply.

Thanks to everyone for the replies to my prior questions about epoxy
and fiberglass (discounting the use of polyester). You help and
experience is appreciated.

I'm planning to build a dodger for my sailboat, still researching and
discovering..

After photographing hundreds of hard dodgers, and studying them
carefully, I know that hard angular corners will not look good on my
boat. I need to round the edges/corners to match the rest of the boat.

What techniques should I research for changing the hard corners where
two ply surfaces connect? How do I shape those round edges smoothly to
have a professional looking curve?

Plywood seems to be a good core for the large surfaces. I may use two
or three 1/4 ply layers glued with epoxy. 1/4 inch ply will allow some
curve to the sides and top, and having multiple layers will provide
strength. This is a 50 foot boat, so 1/2 to 3/4 inch thickness would
not look too flimsy, and the boat can accommodate the weight.

My question at this time is how do you make a smooth tidy round corner
where the sides and top meet, and where the sides and the front of the
dodger meet. It seems that connecting the ply large surfaces together
would add structural strength, but that would cause a hard angular
appearance.

Thanks for your input, (and please forgive my lack of experience).

-Koos.