By Greg Bull — GBI Technical Advisor

I used this quick mold method in order to move the mainsail traveler cleat from the transom of Strings to put it within easy reach of the helmsmen. The part I made had to be strong enough to withstand the loads of the traveler.

A male mold was the best choice for creating the shape to put the cleat where I wanted it. I
began with Owens Corning® Foamular® 150 foam insulation, the “Pink Panther” rigid board foam sold at home improvement stores. It comes in different thicknesses and will bond easily with WEST SYSTEM Epoxy to build thickness or create the desired shape. This foam is inexpensive and easily contoured with basic hand tools. I used a piece that was 2″ thick by 3″ wide and 7″ long. (more…)