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A custom helm seat is constructed from Nidicor honeycomb foam and high-density foam, reinforced with 12-ounce double-bias fiberglass and Total Boat polyester resin.▶ 0:31 To ensure structural integrity, the builders apply fillets at all 90-degree seams before laminating, as sharp corners prevent fiberglass cloth from laying flat without air bubbles.▶ 4:16 The assembly process utilizes vacuum bagging to consolidate the layers, with absorbent cloth placed over the glass to manage excess resin.▶ 1:30 Support beams are fabricated separately using two layers of 12-ounce biaxial fiberglass and two layers of 17-ounce unidirectional fiberglass to achieve rigidity while maintaining a low total weight of approximately 25 pounds.▶ 6:14 The builders note that laminating foam sheets before cutting them into individual pieces prevents edge tearing and improves overall accuracy.▶ 2:51 After assembly, the seat undergoes extensive fairing and priming to achieve a finished surface.▶ 11:04

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