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Fabricating a replacement eyebrow for a hurricane-damaged Antares 44 catamaran requires creating a two-part fiberglass mold from a repaired plug.1:21 After identifying delamination and stress cracks in the original eyebrow, the project involves rebuilding the shape using fiberglass and polyester structural repair putty.1:31 The mold-making process utilizes Duratec gray surface primer, mold release wax, and PVA.7:36 Initial attempts at applying gel coat resulted in severe alligatoring, which was corrected by ensuring proper surface temperature, increasing air circulation, and allowing sufficient cure time between coats.19:31 The final two-part mold allows for the production of replacement eyebrows for Antares and PDQ 44 and 42 models, providing a local alternative to shipping parts from Argentina.30:34 Future steps include verifying the symmetry of the starboard side by comparing paper templates against undamaged vessels and constructing a large oven for thermoforming acrylic windows.33:44 Proper temperature control and surface preparation are critical to preventing gel coat failure during mold fabrication.

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