I ended up doing a three ply box. You can see it underway in pic 1. I did try to use a ply of Innegra in the middle but it just isn't flexiable enough to go around the tight corners so it hit the bin and I used BID.
Pic 2 has it out of the mold and cleaned up and Pic three is a sorry tale. The third box I spent many careful hours on making. In the end I found I could trim about 15mm off the width using the old mold but modified. Its easier to see now the wheel is in and I would have been better off waiting until now to do this step.
Anyway as I flown my 1000+ hours in a Long-EZ I feel the less width on this box the better because its just a bit extra leg room side to side and thats really important for getting in and flexing during flight.
So I just had to do the work again. Its done now and all is right with the world.
