Looking good so far!! Slow and steady progress is the game with a project like this. 

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant

Sanding, sanding, and more sanding.
Now is when the earlier choice to use epoxy is coming home to roost. Using it, I was able to make a lot of progress pretty swiftly after picking this back up. But sanding that epoxy down to final dimension is Hell on Earth. I think I'm about 2 hours in with 80 grit and a tiny little wedge sanding block that I cut to fit into the vane crevice. The progress might be subtle, but I have the front corners sharpened up a lot, the frame has been worked down completely flush with the body, the inside face of the leading edge is smooth, that edge is *almost* a consistent thickness top to bottom (clean up to do) and I've decided that I need to sand the bottom edge level with the ground as datum, so that means sanding it at a downward sloping angle back to front relative to the pattern 

Looking good!  All the time and hard work is now beginning to pay off!

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant

I got the final louver vane replaced, cured, and sanded.
There's still a lot of surface prep work before I'm ready to mold, but I think that's the final look. That's what a 1967 Mustang looks like with 1966 louvers.

No photos this morning. I trimmed the #4 vane too aggressively and have to scrap it...I should have gone a bit slower for my very first task in the morning. I hadn't even had my coffee yet lol

Oh well. It cost me 3c of foam core. I shifted my taks to trying to tidy up the rear edge of the shell. The original line I struck was completely parallel to the sail panel recess line, but that makes the #5 vane too off kilter. With the edge vertical, the bottom edge of the vane is 3" and the top edge is 2.25". It's a very noticeable difference after correcting #3 and #4 that wasn't quite so apparent when my #3 looked derp. I sanded the entire rear line down to be restruck. Best I can make it is 3" on the bottom and 2.85" on the top, but I'm pretty sure that'll be close enough.

I'll get that #4 set after work and update.

Frustrating as it may be, time spend now making the pattern perfect is well spent as then your mould will be perfect and hence translates to a perfect part. More work now, less finishing later in simple terms!

As you have an eye for detail, fixing this now will stop you being annoyed later if the finished mould or part is not perfect.

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant

Alright...a huge pain in the rear, but it must be done






...it would have bothered me forever. I'll create a new #4 before bed.

Repair is cured and seems to have been a success. The durability of the repair area will just have to be found out over time, but it looks promising. I've got some additional rework to do anyway to #3 and #4. That'll likely happen tonight.