Good afternoon all
Here's another load of stuff for you to have a look at.
Its not very interesting I'm afraid but as so many of you are watching my rubbish it's only fair that you see all that is going on.
As the plug was never final finished because I was impatient to get the moulding started I knew I was going to have some flatting back to sort out once the mould was released.
So scribbling around the internal faces of the mould with my black pencil it could clearly be seen where attention was required (it all needed a flat back but some areas more so )
The original sanding marks can be seen easily here so a couple of hours were spent flatting back with 400 and 1200 to get a really nice surface finish and then as explained the other day a final scribble with the pencil to double check that all was good .
Since it will be impossible to glass this whole lot in one go I have to make sure that the important release areas are perfect so with that in mind these areas shown below could potentially cause a problem.
To get around these little issues I needed to make them good with more gel so I keyed up with 60 grit and then painted gel onto the surfaces.
With any 'paint in ' it is vital that the keyed area is much bigger than the repair site itself as the gel need to be flowed out to almost the keyed edge and with at least two coats being applied.
Reason being is that when flatting back you need to have the all important throw on your sanding block and also to fill up the hollow or imperfection or whatever it is you are repairing.
A few smaller other defects had to be dealt with including the small lip at the bottom of the mould which caused me the initial release problems.
Most of it sanded out but these two areas where just a little bit too deep to sand back and yet still keep a uniform shape.
After thrashing my son to within an inch of his life for taking the orange pigment ( he said he needed it for a proper job and not my p*ssing about in the garage crap ) ( how rude

) I finally got to repair the small bits on the base section mould.
The indent for the accelerator pump was hideous looking once released so the easy way to deal with this was to key it with a Dremel and then just simply blob the gel on top and let it flow down over the shape so that when it comes to sanding back all I should have to do is lose the edges.
Like it?
Work smart not hard
The other small bits simply needed a few minutes attention.
All I have to do now is flat back these bits and give it a good polish and we are ready to make the real thing which I cant wait to do now.
I just really hope it works after all this
Catch you later and thanks again for your comments and interest.
cheers
P
PS John
Keep nagging the bosses for that structural course .