Interesting situation. I used to make this product in carbon 10 or so years ago but the plug was made for me. This is a cargo cover for a vehicle and it made from that kinda weird pressed cardboard or wood of some sort. It then was sprayed with some fabric on it that doesn't come off.  What is the best approach of making a plug from it. I have plenty of infusion experience but not much in plug making.  I can do all the flanges and stuff no issue just getting this product to that point. Here are some old pics of it when I was making them. The mold is gone that I used cause the company I was making them for paid for the molds so they were exclusive. That company has been gone for like 7 years and I have to chance to sell another batch.

Only picture and pretty terrible at that of the original mold I could find (again 10 years ago). It is hiding in the bottom right of the picture.  Looks like I was masking it off getting it ready for the clear gelcoat.

How does the fluff respond to a flap wheel?  You could skim over it if it helps smooth the surface then coat with some Pattern-Coat Primer



Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant

I would probably put it in an envelope bag and pull a vacuum, pull the bag tight on the whole surface so there aren't plies and take a quick mold on this and then go from there.

Fasta.. Thanks for the suggestion and it worked perfectly! Took me 2 coats but worked just like I needed it.

Did you also add some board flange areas to it?