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Johan and Malin continue the interior construction of their 50-foot boat by laminating and installing structural bulkheads for the forward cabin.0:59 To minimize waste and cost, they laminate large, non-rectangular bulkheads as single pieces using PET foam, fiberglass, and epoxy, rather than joining smaller panels.2:42 They use a handheld CNC router to cut the foam based on digital design files.5:59 During the vacuum-bagging process, they use a 600-gram and 300-gram fiberglass weave on both sides of the foam.10:42 Johan notes that cutting door openings before lamination caused the vacuum pressure to shift the foam and wrinkle the top fiberglass layer, a lesson he intends to apply to the remaining four bulkheads.19:29 The team temporarily glues the bulkheads into the hull to verify spatial layout before final tabbing.16:04 They adjust for hull thickness variations caused by chainplate reinforcement and floor tabbing by trimming the bulkhead edges to achieve a proper fit.17:34 The forward cabin layout now includes space for closets, a bed, and storage for a bow thruster.23:03

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