This week I stayed off the boat because North Carolina decided to cosplay as the Arctic, and instead I tackled an indoor job: making the biggest mold I’ve ever made—our new eyebrow for Spiffy, the hurricane-damaged Antares 44 catamaran. I used the existing eyebrow as a plug, fixed the major damage with a couple layers of glass and big dollops of polyester structural repair putty, and then spent way too long fairing it because the inside curve and the crisp edge are what makes this part look “right.” I also built up a flange with polypropylene sheet, filled gaps with wax, and set it up as a two-part mold so it’ll actually release without destroying the plug. Then polyester reminded me why it should’ve stayed in the 70s. I rolled on Duratec gray surface primer (don’t do that), sanded the surface-of-the-moon finish back down, waxed, PVA’d, and went for tooling gelcoat—only to get a full-on alligatoring disaster because the plug was sitting around 50°F. The good news: the gelcoat peeled off beautifully thanks to the PVA, I reset everything, tracked temps properly, and the second attempt worked. After nearly 12 hours of hand laminating across both halves, I ended up with a usable eyebrow mold—something that might actually help other Antares/PDQ owners avoid shipping a giant part from Argentina.