Expedition Engineering · video

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Brett and Jade fabricate a composite hard-top enclosure for their boat’s dinghy davits using a closed-cell foam core, carbon fiber, and S-glass.0:21 The structure consists of two legs, each composed of six individual panels, requiring a total of 12 composite parts.12:56 The team uses a parabolic form to shape the carbon fiber and foam, securing the layup with butyl tape and a vacuum bag.3:57 After curing, they trim the excess material with an oscillating saw and sand the edges using a portable belt sander, noting that a stationary sander with fixed guards proved ineffective for the long, curved sides.5:12 To minimize waste, they repurpose scrap carbon fiber to create flat sheets for non-structural cosmetic panels.8:44 Additionally, the team repairs a sun-damaged, cracked engine instrument panel by applying thickened epoxy mixed with chopped fiberglass strands.11:00 They prepare the instrument housing for painting by removing LED lights and sanding the surfaces.18:32

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