Building a Lightweight Composite Shelf for Our Sailboat | DIY Boat Interiors

We're tackling one of the biggest challenges of living on a boat: creating functional storage without adding weight. In this episode, we design, build, and install a custom composite shelf and cupboard unit in our sailboat's cabin. You'll see the entire process, from the initial challenge of "eyeballing" the fit in a space with countless angles, to cutting composite panels with the right blades, and the time-saving trick of pre-painting components before installation. We focus on making it as strong and lightweight as possible, with the final primed shelf weighing just 1.55kg! What you'll learn in this video: The challenge of making things look right vs. being technically right on a boat. How to choose the right jigsaw blades for cutting carbon fibre and composite panels. Our method for gluing and assembling composite parts on the bench. Why we prime and paint before installing components in tight spaces. Using peel ply for a perfect finish on fibreglass tape. This custom shelf adds crucial storage for books and gear, integrates into the boat's structure, and proves that you don't have to sacrifice function for performance. YouTube Video Chapters 00:00 - 01:00: Introduction: Maximizing Space on a Boat The host introduces the episode's goal: to show the design and construction of lightweight, strong cupboards and shelves. 01:00 - 04:16: The Challenge of "Eyeballing" in a Boat Fitting the shelf in a space with many conflicting angles and slopes. The importance of making it look right, not just be technically correct. 04:16 - 06:06: Cutting Composite Panels: Tools & Blades A discussion on the best tools and jigsaw blades for cutting carbon fibre and composite materials without damaging them. 06:06 - 07:14: First Fit Check and Scribing Checking the first cut, dealing with gaps, and explaining how composites allow for filling and fixing imperfections. 07:14 - 11:14: Gluing, Assembling, and Pre-Painting Assembling the shelf unit on the bench and the clever step of priming it before installation to save time. 11:14 - 13:13: The Weight & Pre-Painting Advantage Weighing the finished shelf (1.55kg) and explaining the benefits of pre-painting hard-to-reach areas. 13:13 - 15:04: Final Glue-In and Taping The shelf is glued into place. Using peel ply on the tape for a smooth, easy-to-finish surface. 15:04 - 16:43: Fairing, Sanding, and Final Thoughts The final stages of fairing and sanding. Recap of the benefits: functional, lightweight, custom storage. 16:43 - 18:49: Project Wrap-Up & Teaser for Next Week The finished painted shelf. A teaser for the next video topic: designing and building custom composite hatches to solve water leakage issues. Teaser for Next Video: We're solving a major issue on board next time: keeping the wet stuff out! We'll dive into the design and build of our own custom composite hatches. What's with the mysterious hole in the middle? You'll have to wait and see! Youngbarnacles Membership: Go beyond YouTube. Get detailed tutorials and a community for serious learners. www.youngbarnacles.com SYAS Performance: Our professional design & engineering consultancy for advanced composites, hydrofoils, and owner's representation. https://syasperformance.weebly.com/ Music from https://www.youtube.com/