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Fabricating and installing custom fiberglass door frames for a catamaran interior requires a multi-step process of molding, bonding, and fairing. To create the frames for three head doors, the builders laminated six layers of 1208 fiberglass to achieve a thickness of approximately 3/16 inch.1:05 Rather than constructing complex molds for each unique door opening, they created flat panels, cut them into 1.5-inch strips, and bonded them to the bulkheads using epoxy thickened with colloidal silica.1:50 A one-gallon Total Boat container served as a template to create the radius for the door jams.4:23 The finishing process involves repeated applications of Total Fair epoxy fairing compound, followed by sanding to address pinholes and low spots.8:08 To identify remaining imperfections before applying high-build primer, the builders use a guide coat made of blue Dicom dye mixed with denatured alcohol.11:43 A mini belt sander helps remove excess thickened resin in tight areas, though manual sanding remains necessary for final smoothing.9:46

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