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The construction of a custom dodger arch requires significant structural reinforcement, including the addition of carbon fiber layers and internal support legs to manage heavy loads.5:43 To ensure rigidity, the team experiments with sandwiching foam between carbon fiber layers, finding that two-layer construction significantly increases stiffness compared to single-layer applications.7:05 The fabrication process involves building window frames with specific lips for mounting, fairing the surfaces with filler, and sanding down high spots.5:19 To remove mold release wax from the composite surfaces, the team tests various solvents before finding that soap effectively cleans the material.3:36 After completing the structural gussets and fairing, the team weighs the dodger arch to assess its mass, discovering it weighs 99 pounds—considerably less than their initial estimate of 130 to 140 pounds.13:31 The project focuses on achieving a balance between structural strength and manageable weight for the final installation.

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