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Construction of a custom sofa for a 50-foot sailboat involves fabricating stiff, lightweight sandwich panels using carbon fiber and woven fiberglass. To achieve the necessary structural integrity for the deck salon, the builders laminate two 2.7-meter-long panels in a single vacuum-bagging process, utilizing approximately 27 to 28 square meters of carbon fiber.5:07 The process requires precise stacking of lengthwise and 90-degree carbon layers topped with 300-gram woven fiberglass, followed by saturation with epoxy.6:40 Once cured, the panels are cut to shape and tabbed into the existing bulkheads using additional fiberglass and carbon strips to ensure full joint strength.1:16 The resulting carbon-fiber sandwich panels offer significant weight savings and stiffness compared to marine plywood, though they require more intensive preparation and higher material costs.14:43 The completed sofa structure provides a raised seating area with 360-degree visibility and is designed to convert into a berth using adjustable pedestals and custom mattresses.21:27

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