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To thermoform replacement windows for a hurricane-damaged Antares Yachts 44, the project requires a custom-built, large-scale aluminum oven.0:35 The construction process involves riveting aluminum panels to an inner frame, using high-temperature silicone for joint sealing, and installing a heavy-duty hinged lid.2:29 To prevent heat loss and protect the acrylic from insulation contamination, an outer enclosure is added to the oven, with high-temperature silicone strips serving as thermal breaks between the outer skin and inner frame.4:10 Initial testing at 100°C confirms minimal vertical heat stratification and effective insulation, as the exterior remains cool to the touch despite the internal temperature.21:04 The project aims to produce custom acrylic windows for approximately $5,000 in materials, offering a significant cost savings compared to the $20,000 market price for factory-made replacements.10:31 Future steps include testing heat distribution across larger surface areas and evaluating plaster of Paris as a mold material for the thermoforming process.24:06

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