Brief Description: O2 Console - Turning the plug into a mold
I used products from Ill Street Composites for most of this work. This includes the Duratec filler, gelcoat, fiberglass mat and polyester resin. There are lots of videos and Web pages outlining steps, tips and techniques.
One glitch is that I bought 2 pints of polyester resin from Ill Street (I should have just gotten a gallon). One can was fine but halfway thru a layup, I opened the 2nd pint and found that it had cured into a gel. It was a virgin can so I know I didn't do it but the folks at ill Street didn't quite buy it (and I don't blame them) In the end I just had to buy a replacement. This time I just got a gallon.
Several layers of mat and resin had to go on but it didn't look so neat after I ran into the ruined can of resin. No harm though, just tool aesthetics.
Note the two PVC nipples I molded into place. I knew that getting the plug as well as the finished part out of such a deep mold would be a challenge but some compressed air could help a lot. It did the trick quite well.