How we made this MASSIVE MOLD! - Episode 96
7 February 2021 · 17 min · 387K views · West Palm Beach
What this video covers
The crew repairs the damaged transom of their boat, *Blues Traveler*, by creating a fiberglass mold from a donor vessel, *Orion*.2:24 To ensure a precise fit, they avoid building a single-piece mold, which risks misalignment due to structural shifts between the two hulls.5:39 Instead, they construct a two-part mold separated by a flange, allowing the sections to be bolted together and removed individually.4:46 The process begins by waxing the donor hull to prevent the new fiberglass from bonding to the original surface.5:42 The team applies orange tooling gel coat followed by multiple layers of fiberglass, carefully managing the curing temperature to prevent warping or heat damage to the donor boat.5:49 After the mold cures, they successfully release the two sections from the hull, revealing a smooth, accurate surface.15:54 The crew plans to use these molds to laminate the new transom section, which will then be married to *Blues Traveler* for final structural repairs.3:29
Boats in this video
More from Sailing Parlay Revival
From Sailing Parlay Revival — see the channel’s boat, crew, and every analysed video.
The Sailing Directory Newsletter
One email with the fleet's best finds — the moments, boats, and stories worth your watch time. Enter your own address to get your own copy.