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Johan and Malin fabricate custom high-density fiberglass inserts to reinforce high-load deck areas on their boat, replacing PET foam core at locations designated for cleats, stanchions, and the windlass.1:28 To avoid the high cost of commercial G10 panels, they laminate 33 layers of scrap fiberglass and epoxy into 25mm-thick plates.1:50 The process involves vacuum-pressing the layers, followed by sanding and fairing to achieve a uniform thickness.3:23 These solid inserts are then integrated into the deck structure using thickened epoxy and tabbing.9:01 To manage structural loads, the windlass plate is tied into the bulkheads and stem with knees, while the cleat inserts are reinforced with carbon fiber to transfer lateral forces across the hull.14:14 The team plans to divide the remaining foredeck panels along existing deck beams to simplify installation and ensure a fair curve.21:17 They prioritize structural integrity by tabbing these sections into the hull and using knees to spread loads from deck hardware.22:49

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