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Fabricating a custom fiberglass cross-support for the aft deck of a Bertram requires building a flat, structural base that accommodates an existing arched component. To bridge the half-inch gap between the new support and the arched piece, nine layers of 1708 biaxial fiberglass cloth are laid up wet-on-wet using polyester resin catalyzed at 1%. Staggering the lengths of the fiberglass layers creates a gradual taper, which minimizes the need for excessive fairing compound during final shaping. Because the new support uses polyester resin and the existing arched piece was reinforced with epoxy, the surfaces must be coated with wax-containing gel coat to ensure a full cure before bonding. The two components are dry-fitted and will eventually be joined using thickened epoxy and mechanical clamping. Achieving a flush fit requires dishing the underside of the support's ends to account for deck curvature. Custom one-off fiberglass fabrication demands iterative trimming and fitting to ensure structural integrity and proper water drainage.

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