Sail Lifevideo
⛵️ Thermoforming thick acrylic windows for our hurricane-damaged catamaran, part 1. Ep 668
March 1, 2026 · 25 min · 85K views · Marinecraft, Florida
What this video covers
To replace damaged windows on a 44-foot Antares catamaran, the owner constructs a custom, top-loading electric oven designed to thermoform 10mm-thick acrylic sheets.0:22 The project aims to avoid the $20,000 cost of professional replacements by DIY-fabricating the windows, which require complex compound curves.1:02 Before construction, the owner verified the structural integrity of the cabin top by comparing a paper template of the port eyebrow against a neighboring Antares 44, confirming the boat’s hull shape remains true.2:59 The oven, measuring approximately 7 feet by 4 feet, is built from aluminum sheets joined with over 1,000 rivets and insulated with rockwool.4:04 The design incorporates fin heaters, high-temperature fans for air circulation, and PID controllers to maintain a 350°F forming temperature and a 220°F drying cycle.6:24 The owner also uses a CNC machine to fabricate aluminum standoffs for the heaters and a perforated heat-deflector plate to ensure even heat distribution and prevent hot spots during the thermoforming process.20:55
Boats in this video
More from Sail Life
From Sail Life — see the channel’s boat, crew, and every analyzed video.
The Sailing Directory Newsletter
One email with the fleet's best finds — the moments, boats, and stories worth your watch time. Enter your own address to get your own copy.