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Johan and Malin construct the cockpit sole and a large integrated hatch for their 52-foot sailboat using PET foam core sandwich panels.0:16 The process involves cutting the foam to size with a handheld CNC router, beveling edges at 45 degrees, and laminating the panels using a vacuum bagging technique.1:01 Johan details the function of each layer in the vacuum bag: the vacuum bag itself for atmospheric pressure, breeder mesh for uniform pressure and excess resin absorption, perforated release film to prevent resin starvation, and peel ply to create a ready-to-bond surface without amine blush.4:23 The sole is installed with a 1% slope toward the drains to ensure water runoff.14:59 The hatch design incorporates double seals and increased foam thickness to provide the rigidity required to support a cockpit table base.15:45 The project concludes with the installation of the sole, while the crew monitors storm Amy, which brings wind gusts of 34 knots and leaks into their workshop.20:43

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