Much Improved Salon

Well, like most projects, the settee cushions took a bit longer than I anticipated. After getting the foam cut and test fit, I started cutting out the fabric. The wood burning tool I used to cut the Sunbrella material worked well, but it is a slow process. Not having the material unravel is well worth the effort.  I used a permanent marker to trace around the plate (top and bottom) patterns of the cushions. The straight boxing (side pieces) were just measured, but patterns were used for the curved boxing of the back cushions. Although the fabric doesn't have stripes per-se, it does have a pattern or grain so care had to be taken while positioning the patterns to make it all look right.

The old, cracking salon cushions.

Sewing the pieces together to make the cushion covers is fairly straight forward and there are plenty of tutorials at Sailrite on how it is done.  The trick was getting the zippers installed along the seams the same way it was done on the original cushions. The trick I found that worked best was to sew the boxing together, then starting about an inch from the end of the back seam, sew a couple inches of the boxing on, placing marks on the material.  I would then temporarily sew the gap in the middle where the zipper would be using the largest stitch possible.  From that, I could position and add the zipper without things moving around too much.  Once the zipper tape was attached, I would install the slider, rip open the seam and sew across the ends of the zipper to lock everything in place.  From there, I could sew the remaining boxing to the plate.

Making new foam inserts for the cushions.

The Sailrite machine works very well for sewing heavy materials and zippers together. Although not a fancy, computer controlled machine, I have no doubt that these machines will last a lifetime even under pretty heavy usage. I think we will be holding onto it even after the boat is gone.

I applied polyester batting to the foam using 3M 77 spray adhesive.  Then began the process of wrestling the foam into the covers.  Since the covers are actually a bit smaller than the foam itself, this can be a bit of a process, but having the foam fit tight makes the cushion look a lot better.

After the bottom cushions were done and test-fit on the boat, I checked the patterns for the seat back cushions. The original back cushions didn't line up all that well, and I hoped to at least improve upon the alignment.  I adjusted the patterns a bit and went to work on the seat backs.  Sewing the large curved cushions was the most difficult as there are no corners to align.  The front plates are longer vertically and shorter horizontally than the back plates.  I had to make center marks and pre-pin the pieces together before sewing them up.

The new cushions. I think they are a vast improvement.

So, it was a bit more time consuming than I thought, but I think the result was well worth the effort.  The new cushions look far better than the old cracked vinyl ones and I think are quite a bit more comfortable too.  Hopefully the new owners of the boat will appreciate them.

Dodge This

To say I've been a bit concerned about this upcoming run south is probably an understatement.  It is not the trip itself, but the cold temperatures that make me not all that happy about it.  Last year when I made the run from Deltaville down to Georgia I said I didn't ever want to do that in November again...and, well, January wasn't the change I had in mind.  That time I had the soft bimini with the integrated front dodger and while it wasn't the most pleasant of trips, having the dodger to keep the chilly wind out of our faces was at least a little help. Now that we have this nice new hardtop with its increased forward view, the old dodger just doesn't fit.  That is, until now.

Deciding that we really need a dodger, I came up with a plan to retrofit our existing dodger to the new top.  It won't be pretty, but at least it will be something until we can get around to building a new enclosure.  Given neither my wife nor I want to take on another big project until we can get the fun to work ratio more in balance, I wanted this temporary solution to be able to last at least a little while.

The plan was to take the existing dodger and some of the pieces from the old soft top to create a new dodger that will fit the new top.  The old soft top already had the zippers that mate up with the old dodger and it also had a bolt rope where it was attached to the rear of the arch.  If we attached the old top to the dodger, cut it to fit the new top, and add the bolt rope to fit the yet to be cut slot in the front rail of the new top, we should have a solution.

To start I needed to cut the bolt rope slot in the bottom side of the forward handrail of the new top.  I created a gauge using some left over wood from the hardtop mold so I could draw a line in the center of the rail with a pencil.  I drilled two holes at the two ends of the slot that I will elongate so there is room to insert the bolt rope. I then used my vibrating multi-tool to carefully cut the slot.  In hindsight, I probably should have cut the slot before we mounted the top as it was more difficult to cut laying on my back on the deck.  After cutting the slot, I determined that the blade on the multi-tool created a slot that was just too thin and the bolt rope would likely bind while trying to slide it in place. I tried wrapping a stick-on sanding disc around the multi-tool blade and that widened the slot but quickly chewed up the sandpaper and left bits of it inside the slot.  Off to the store to see if we could find a solution.  What we found was a grout removal blade for the multi-tool.  This is basically a sandpaper looking metallic blade that should function like the sandpaper without wearing away.  It did the trick and widened the slot to about double the original gap.

The bolt rope slot and access hole in the front rail.

I used the multi tool to cut the holes in the ends into more of a teardrop shape.  This didn't really provide enough access to insert the bolt rope and so I took my rotary tool and a small drum sanding attachment and elongated the hole into an inch and a half opening.  That did the trick.

To clean up the cut of the slot, I took some excess 3/16 line and wrapped the stick on sanding discs around it.  This essentially made an abrasive segment of bolt rope. It was used to clean up the edges of the slot to allow the regular bolt rope to easily slide.

Getting the plastic shavings out of the slot was an interesting task.  After some work with the shop vacuum and a thin screwdriver, we were able to clean everything up and now we have a nice bolt rope slot along the bottom of the front rail.

The original dodger was slid into its original lower bolt rope track.  The old bimini was attached to it and pulled tight up over the new hardtop.  I carefully marked where the old bimini material met the lower edge of the new bimini rail.  It was a challenge to try figuring out how we could attach the old curved corners to the new, wider top, but we did the best we could.  After getting everything marked, the bimini was removed from the dodger and cut so there were two extra inches of fabric beyond the marks to allow for creating a double hem. Excess zippers, hardware, and other original mounting bits that are no longer needed were removed.

Marking and cutting the old bimini segment.

I used straight pins to temporarily hold the hem in place and then broke out the Sailrite machine and started sewing.  I finished the cut edges and then sewed on the bolt rope that was scavenged from the back of the old bimini.  I even tried a zig-zag stitch for one of the runs on the bolt rope, not because it was needed but more for the practice using the machine.

Sewing up the old bimini strip to make the "new" dodger.

The end result turned out pretty well.  Better than I expected in reality. (I wonder if my junior high home economics teacher would be proud?)  It isn't that pretty and a properly fitting enclosure would provide a better view, but it should provide us at least some protection from the wind and rain while we make our way south.

The temporary dodger. You can see how much larger the
view forward is now compared to the old dodger.