Expedition Engineering · video

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A pair of sailors construct a custom composite arch and hardtop for their sailboat to support a dinghy davit system and solar panels.2:23 Working in a shared workshop, they design the structure using Fusion 360 and Illustrator, then build a full-scale mockup using MDF to verify angles and curves.3:16 They select closed-cell foam for the final build to minimize weight and prevent water absorption during the epoxy layup.18:40 After initial difficulties with routering and battery-powered tool limitations, they refine the geometry and successfully cut the foam panels to fit the desired curve without needing to score the material.20:27 The team prepares the workspace for vacuum bagging, including leveling the form to prevent resin pooling and installing a shutoff valve to maintain vacuum pressure.24:38 They plan to use the finalized foam templates for subsequent composite layups.24:03

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