Max measures keel laminates. The keel is made with 80 layers of carbon. The outermost unidirectional layers of carbon fiber are oriented longitudinally for increased stiffness and strength.

While Max oversees the operation, Brendan mixes epoxy and Mike and Dan simultaneously build opposing sides of the keel

Pealply is applied to the keel laminates.

We put breather on top of the laminates to let the vacuum pump pull an even vacuum. Note the bridge of breather near Brendan. Dan and Brendan prepare the bag.

Vacuum bag applied with vacuum sealing tape. The vacuum will decrease voids in the laminates and increase fiber volume fraction, thus increasing specific modulus and strength.

Max, Dan, and Brendan check for leaks.

Max drilled the hole for the motor shaft to go through, and begins building the motor mount with Divinycell and carbon.

Max builds part of the motor mount with Corecell

Dan uses a pneumatic cutting wheel to cut extra material from the motor shaft

The motor mount. The blue tape is used to protect the rest of the carbon when putting in fillets. The fillet material that we're using is epoxy mixed with a high density filler.

Max begins to shape the rudder. Built with a birch plywood core, it's laminated with three layers of carbon fiber and has unidirectional carbon reinforcements.

Max cuts carbon for the rudder. The rudder, like the keel, hull, and deck, will be vacuum bagged.

The keel comes out of the vacuum bag. Max is mixing epoxy with high density filler which he'll apply to both halves of the keel.

Max applies the epoxy to one side of the keel

Brendan mixes the epoxy for the keel

Weights are used to secure the keel. We don't clamp it because we don't want to displace all of the epoxy. Not seen here are stabilizing clamps that keep the assembly from sliding on the epoxy.

Matt and Max prepare carbon to reinforce the motor mounts.

Dan prepares the motor mount fillets for carbon strips.

Lucy, our professional puzzle maker, puts the finishing touches on her latest puzzle.