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A DIY project to thermoform replacement acrylic windows for an Antares Yachts 44 catamaran succeeds after extensive experimentation with custom molds and a 6000W electric oven.0:31 The process involves creating a male mold from a fiberglass plug taken directly from the boat’s cabin top, then covering the mold surface with grade F1 felt to prevent imperfections during the forming process.3:39 To avoid surface blemishes, the acrylic sheet is heated on a clean aluminum surface to approximately 149°C.16:56 Once pliable, the material is draped over the mold and allowed to cool, which eliminates springback.17:50 The final window is trimmed to size using a plywood template and a flush-cutting router bit.18:12 While this method produces a successful result, the host notes that hanging the acrylic vertically during heating—a technique used by professional window fabricators—would further reduce the risk of surface contamination.14:58 Future iterations will utilize slightly larger molds to minimize edge wrinkling.20:32

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