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Rob's REBVAIR Project
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Date:  8-2-2016
Number of Hours:  4.00
Manual Reference:  
Brief Description:  Windshield Install Part 4: retainer finishing

Image 1 shows the retainer is trimmed using the Fein multi-tool. All the layers added up to at least 1/8" thickness so it is particularly beefy. The windshield also fits very nicely against the retainer.

Then it was ready to add filler.
I followed the composites finishing advice found in this document on the web:

http://curedcomposites.com/finish.html

The procedure makes a lot of sense to me: add way more filler than you need, then sand it all down flat....once. A long flat surface is certainly more straighforward; on this very curved retainer, it is a bit more complicated. Nevertheless, I thought the principle sound.

Image 2 is after application of a layer of very dry micro, thinned with a little rubbing alcohol. One of the other builders suggested the rubbing alcohol, and it made spreading this micro much more feasible. It's meant to be ugly and should be 1/8 to 1/4" thick.

Image 3 is what it looks like after knocking down the ugly layer of micro with 60 grit paper. I painted the retainer black before the micro was applied so that you can see the dark high-spots appearing as the sanding progresses. There are still some obvious nicks and holes, but these get attended to in part 5..
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after initial 'rough' trimming

after initial 'rough' trimming

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heavy micro layer

heavy micro layer

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after 20 min sanding 60 grit

after 20 min sanding 60 grit

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