First step: rough cut and generous bondo use.
This is what it looks like after hitting the belt sander and rounding the profile a bit.
Gray primer helps show irregularities in the shaping process.
A parting tray is built to create a line for dividing the two mold halves.
The plug is positioned and dammed up with bondo to create a perfect parting edge.
Primer is sanded and polished to create a nice finish on the parting flange. A huge flange was chosen to allow for resin infusion process if I decide to go that way.
I walled up the parting tray to avoid the mess of spilled resin, overspray, and cutting the mold edge after layup.
Black tooling gel was sprayed through a siphon gun until about 20 mils thick to create a hard, durable surface capable of producing many parts.
Two layers of resin and chop fiber were layed up on the tacky gelcoat to stabilize it and prevent shrinkage overnight. This is where it's at now.. more later.
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