Expedition Engineering · video

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Fabricating a carbon fiber sailboat davit leg requires a multi-layer layup process using closed-cell PVC foam as a core.2:56 To improve efficiency and structural integrity, the team cuts all components—foam, carbon fiber, peel ply, breather cloth, and vacuum bagging film—before beginning the epoxy wet-out.8:36 Applying masking tape to the carbon fiber before cutting prevents fraying, though the tape must be removed carefully with acetone to avoid pulling fibers.9:24 The layup sequence involves wetting out diagonal and vertical carbon fiber layers, sandwiching the foam core, and applying the vacuum bagging materials as a single unit to prevent stretching or mangling the wet fabric.13:44 Despite using a vacuum bag, the team struggles to maintain a perfect seal, likely due to small pinpricks in the film.17:02 They compensate by using weights to ensure contact and running the vacuum pump only until the excess resin is drawn into the batting.17:31 A new heater is installed to reduce cure times, which previously reached 48 hours in cold shop conditions.18:17

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