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⛵️ Plaster molds and counter weights. New windows part 4! Ep 671
22 March 2026 · 26 min · 74K views · Deltaville, Virginia
What this video covers
Mads continues the DIY restoration of his 44-foot Antares catamaran, Spiffy, by developing a custom electric oven to thermoform new 10mm acrylic windows.0:11 To avoid the $20,000 manufacturer cost, he tests plaster of Paris as a low-cost mold material.4:07 He successfully casts test molds using a 400g to 240g powder-to-water ratio, noting the exothermic reaction reaches 90°F before cooling.4:55 To improve oven ergonomics, he installs a counterweight system using steel wire, pulleys, and lead weights, allowing the heavy lid to open easily with two fingers.14:08
During thermoforming tests at 170°C, the plaster molds produce a smoother acrylic surface than previous aluminum tests, though uneven heat distribution leaves the center of the acrylic under-formed.23:58 Mads plans to experiment with high-temperature plaster, secondary heat deflectors, and longer soak times to achieve uniform heating.24:38 Additionally, he measures the cockpit seating on a nearby Antares to guide the reconstruction of Spiffy’s cockpit, planning to use seven sheets of 3/4-inch Endura panels for the project.3:28
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