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Johan constructs a bow cone for a 50-foot custom sailboat by laminating 20-millimeter oak slabs.15:39 To achieve the correct profile, he builds a custom jig to guide the slabs through a planer, ensuring the section cuts align with the 3D design.1:11 After rough-shaping the cone, he glues the assembly directly to the hull stem using epoxy.10:49 Because the oak thickness prevents sufficient clamping pressure with straps alone, he adds screws to ensure a tight bond and proper epoxy squeeze-out.13:03 Once cured, he fills the screw holes and sands the surface with 40-grit paper to prepare for fiberglassing.15:56 The finished bow features 250 millimeters of solid oak, designed to provide structural strength and impact resistance, supported by a watertight bulkhead in the first three meters of the hull.16:35 Johan notes that using thinner 10-millimeter CNC-cut slabs would have reduced the steps between layers and simplified the final shaping process.15:39

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