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Date:  1-25-2016
Number of Hours:  6.00
Manual Reference:  
Brief Description:  Overhead fab continues yet again

I added a foam flange to the overhead plug to create a flange on the mold. The flange is needed to use vacuum seal tape for vacumme bagging. I am going to use a technique on the actual part called resin infusion. It makes a part with no voids and minimum resin. It also allows all of the plys to be set up perfectly and in position before any resin is added.

4 coats of release wax and a cote of PVA and the mold is ready.

The first run at laying up the part was a bust. I didn't pre-cut enough glass and I mixed up too much epoxy at a go (600 cc). I struggled to get the glass to lay in the tight corners of the recesses, then the resin exothermed. So with less than 25% covered I gave up and went in the house. The good thing is the next day I pulled what I completed and it was better than I thought. It released well and did not damage the mold.

Next try was more successful. I precut lots of glass and mixed epoxy at 300 cc per mix. 5-6 layers of 6 oz glass. I cut 5 pieces to fit in and mostly fill each recesses. This allowed thelarger pieces of glass to lay on top and not have to make the sharp bend. Same thing along the flanges to avoid the sharp bends. It was successful except where I didn't place the glass well.

As you can see below, I left bubbles that will need to be filled. Nothing that can't be fixed with a little filler.
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boarder added

boarder added

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plug glassed to form a mold

plug glassed to form a mold

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mold shell completed

mold shell completed

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