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A boatbuilder named Ben constructs the full-size plywood-and-timber foundry pattern for the cast iron ballast keel of a new schooner, Malabar IV, built to John Alden's original plans.2:34 The pattern must be made slightly oversize — approximately one-eighth inch per foot in each dimension — to compensate for iron shrinkage in the sand mold.2:50 Ben cuts the two plywood side panels, marks station lines, then fits long right-angle off-cuts from previous mast-making as corner battens along the inside edges to anchor the top and bottom panels.2:58 Internal plywood spreaders, cut to the correct width and angle, will hold the mold's belly shape, which narrows at each end and widens in the middle.6:40 The central design question is whether to follow Alden's specification and have a foundry cast an iron keel, or to home-cast a lead keel instead — a decision still unresolved at the time of filming.5:43 Ben has previously home-cast lead ballast himself but notes iron requires a commercial foundry.2:15 Patterns for the stem, sternpost, and timber keel are already complete and stacked ready for use.1:35

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