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Johan and Malin construct the deck saloon sole for their sailboat using 25-millimeter PET foam panels reinforced with unidirectional carbon fiber.1:50 To maintain headroom while ensuring structural stiffness, they replace traditional fiberglass with carbon fiber, which provides three to eight times the stiffness at a similar weight.4:27 Johan manually orients the carbon fiber strands in alternating directions to ensure multi-axial strength, then caps the laminate with a layer of woven fiberglass to protect the carbon from abrasion and impact.2:07 The crew also installs Roxtec watertight cable transits into the bulkheads to manage electrical routing through the vessel's interior.11:36 After laminating the sole and sofa base components, they temporarily position the panels to test the deck saloon layout and sightlines.18:42 The carbon-reinforced panels exhibit significant rigidity, providing a stable platform for the interior living space.16:44

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