I wasn't happy with the blister for the O2 cylinder riveted to ally sheet, so I decided to mould the entire floor panel from carbon fibre instead.
I made an MDF mould with a joggled recess for the door panel and a stepped-down joggle overhang for the middle floor panel, which will be held in place with 1/4 turn camlocs. I did exactly the same to the other side of the board to remake the port floor board with the same blister, which will make the seat feel symetrical for the passenger under high G.
When that was done I waxed the surface, waxed on the old carbon blister, waxed some more, PVA'd, layed-up the carbon fibre and then vacuum-bagged the lot. Later I used an ally rod to roll excess resin away from the fillet around the blister, which should minimise the sanding before priming (hopefully).
