Acorn To Arabella · video

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Steve and the crew construct a concrete mold to cast a 10,000-pound lead ballast keel for a wooden sailboat.0:20 Because smelting iron is cost-prohibitive and requires specialized equipment, the team opts for a lead keel they can pour on-site.0:37 They build a reinforced box using double-ply plywood, angle iron, and strapping to withstand the pressure of the concrete and molten lead.4:07 To prevent moisture-related explosions during the pour, they prepare a level surface with a plastic moisture barrier and plan to use a flame weeder to dry the concrete thoroughly before introducing the lead.3:43 The process involves creating a plug, pouring concrete around it, and removing the plug to leave a cavity.8:09 The team intends to insert wooden cores into the mold to create pilot holes for the keel bolts.11:02 They plan to cover the mold with plywood and weights during the pour as a safety measure against potential steam-driven eruptions.12:09

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