To create edges I use glass putty (it's like normal putty, but it doesn't dry and you can use it several times); to polish it you could start with 1000 sandpaper and after 2000, I use wet sandpaper..and after for glossy some wax or polish will work well, matthieutje65 knows well, you can ask him

Because of the polypropylene workboard i could crack the mould loose without to much strain on the mould itself.


You can see the expanding foam, pp tape and plasticine used.

I did a quick check on the part itself and it came loose really easy, no locks, and the pp tape almost fell of.
This regular packaging tape seems to be the solution for all my problems =)


The part itself had a bit of a rough surface.
Any tip on whats the best way to polish this?

Thanks
8hours in the resin curing now,
Was a bit to short on the resin, but i think it should be sufficient.

looking good this far!

Matthieu Libeert
Founder MAT2 Composites X Sports
website: www.mat2composites.com

Thanks.
Mould is on its way =)





Gel was applied last night, so it is now ready for the coupling coat.




I'll post the result as soon as im done.

Yeh PP packing tape will be fine, it is just the adhesive you don't want to expose to the resin.

Yeah i recon.
Was hoping there was another way.
There is some regular packing tape where the film is polypropylene
http://adhesive-tape-converting.mbktape.com/viewitems/film-tape/polypropylene-pp-film-tapes?

If i put the adhesive side towards the part, then the tooling gel should not stick to this tape right?

btw. i work on a polypropylene board which keeps basically everything from sticking, including expanding foam.

I think you will struggle getting anything to stick to the foam. Tape may work, but it won't stick nicely. Hopefully the foam just gives enough support to the tape to allow you to get the gelcoat and reinforcement on.

Thanks guys.
I decided to start with another piece from the underside that is not broken, it got some damage, but its easily sorted.


Since the part has several large gaps i tried using expanding foam, has anyone tried this?


As you can see i have started cutting the foam and the plan is to use the uni-mould system.
I have ordered lots of stuff from EC, Flash tape included.
And i recon i can cover the "swiss cheese" with this tape and then cover the whole part with tooling gel.
The problem is that the EC package hasnt arrived yet, so the question is, is there anything else i can cover with?
I got

The reason i tried expanding foam is that i found it to be to much hassle with cutting polypropyleneboards to fit everywhere.
I got #8 mould release, and lots of plasticine, maybe a thin layer of plasticine to cover up the foam holes?
As you can see the part is in a bit of a rough condition, so i am prepared to sand and polish the mould once its done.

Any suggestions appreciated!

I would hot glue some signboard behind the holes and then fill them with plastercine.

If you treated yourself to some of the heatproof/release tape you could simply fill the hole with cardboard or what ever and then release tape over that, the mould will release from this no problem.

while your at it use the signboard to make flanges and seal any holt holes with the release tape.