Expedition Engineering · video

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Fabricating structural legs for a boat’s dodger arch requires balancing strength and weight while maintaining precise curves.2:23 The project involves laying up S-glass and epoxy over a foam-core form to create rigid, lightweight supports.4:52 Initial attempts using vacuum bagging on a single leg resulted in voids and puckering, prompting a shift to a wet-layup method.5:59 This alternative technique involves wetting the fiberglass, squeegeeing out excess epoxy, and wrapping the assembly in plastic to compress the layers.10:30 Comparing the two methods, the squeegee-and-plastic technique produced a leg 20 grams lighter than the vacuum-bagged version while achieving a similar finish.11:37 To ensure structural integrity for mounting, the team incorporates a metal base plate into the carbon fiber layup, allowing for secure attachment points.14:32 Proper timing of the epoxy cure is critical; the material must reach a tacky state before adding subsequent layers to avoid excessive heat or thickness.9:40 Using a test piece, such as a chart plotter box, helps gauge the optimal curing stage for secondary layups.10:09

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