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Johan and Malin are building a new boat in a barn in Sweden, currently focusing on laminating the internal hull skin with fiberglass and epoxy.0:09 After completing the starboard side, Johan transitioned to the port side, utilizing a custom-built hanger for the fiberglass roll to facilitate solo lamination.5:49 The process involves sanding, cleaning surfaces with alcohol, and working through the night to ensure consistent application.2:35

The project also involves transitioning from plywood to PET foam for bulkheads and interior structures.7:45 This material choice saves approximately 1,000 kilograms of weight compared to plywood and costs roughly one-third the price of traditional PVC foam.8:20 The selected PET foam has a density of 100 kilograms per cubic meter, which provides structural strength comparable to 80-kilogram PVC foam.9:33 While the foam core requires additional labor to laminate both sides with fiberglass, the weight savings allow for more ballast in the keel.8:45 The hull interior lamination is now complete.18:13

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