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Johan and the crew are constructing a custom deckhouse roof for their boat, utilizing a multi-piece design to accommodate limited workshop space.3:11 The roof consists of five sections, each measuring 1,040 millimeters wide, totaling 5,200 millimeters in length.14:26 Johan fabricates a mold to produce these sections upside down, allowing for integrated rib installation during the vacuum bagging process.3:27 During the mold preparation, Johan discovers a critical error: he mistakenly programmed the CNC machine with a 34-meter diameter instead of a 34-meter radius, resulting in an incorrect curve depth.8:35 He corrects the cutting file and re-cuts the foam before proceeding with the lamination.9:36 The final layup for each panel includes three layers of 600-gram biaxial fiberglass on both sides, with unidirectional carbon fiber added to the ribs for structural tension and stiffness.22:27 Johan notes that while mixing carbon and glass is often discouraged, it is acceptable here because the materials serve different load paths—torsional stiffness for the glass and tension for the carbon.23:25

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