Expedition Engineering · video

What this video covers

Fabricating a custom hard dodger and hardtop for a sailboat involves a multi-stage process of carbon fiber layup, fairing, and high-build priming. The construction utilizes foam cores reinforced with wood blocks at mounting points to ensure structural integrity for screw attachments.6:19 To maintain a watertight seal, PVC conduits are integrated into the davit legs to separate dinghy lift lines from electrical wiring.5:50 The process requires repeated cycles of applying fairing filler, sanding, and coating with high-build primer to eliminate surface waviness and achieve a smooth finish.12:39 Residual wax from mold-making can cause adhesion failures in fairing compounds, necessitating thorough cleaning before further application.10:20 During the final installation phase, the team removes the existing canvas bimini and temporarily secures the mast with topping lifts and a spinnaker halyard to safely disconnect the backstay.18:23 The lightweight carbon fiber structure is then positioned and glassed into place.19:55 Consistent sanding and fairing are the primary requirements for achieving a professional finish on custom composite marine structures.20:47

More from Expedition Engineering

The Reason We’ve Changed (27)Aug 2026One Year Update - Custom Carbon Fiber Hardtop (26)Jul 2026Wake-Up Call: The Critical Failure That Could Have Been VERY BAD (25)Jun 2026Our Boat Kept Getting Slower. This Was Why. (24)Jun 2026

From Expedition Engineering — see the channel’s boat, crew, and every analysed video.

The Sailing Directory Newsletter

One email with the fleet's best finds — the moments, boats, and stories worth your watch time. Enter your own address to get your own copy.