To fill gaps and "one use" radius, plasticine works nice. But it can deform under pressure, so be carefull depending on your consolidating process.

I don't want to bond the flange permanently to the part; mostly because it is a two part mould and I need to get the flange off again, and partly because I want the plug to be reusable.

use some polyurethane kit or just regular tec 7, make the corner smooth by cutting to rest away, and then wax the corner extra good?

Is there a solution to the problem of the flange moving away from the part creating a gap in the wax? I'm having endless trouble with this with the part I'm currently making, it's driving me mad. I'm at the stage where I'm about to pump the gaps fill of hot glue, but I don't want to create issues. I've tried using more hot glue to hold the flanges in place better, but it just won't stick to the plug and the slightest pressure causes it to drop away. 

If neatly defined edges is a priority on that part then you stand off the flange from the edge of the part. Eg cut a shaped bit of sign board, bond it to the flange then hot melt glue the flange to the part.  The actual flange will then be 4mm lower down leaving a nice gap for filleting in some wax while still being able to retain edge definition.

An arguably better solution is to angle your flange.  If you are looking at wet lay or resin infusion, if you keep it as you have, you will have a sharp 90 degree bend right on the edge of the part which you need to bend the carbon around.  If you can reduce this to a less sharp bend then the better chance of getting the carbon to conform closely and the less chance of air voids or bridging occurring.

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant

You could use a fillet shaper once you have the wax forced into the gap. Use a squared off shaper to give you the square shoulder you started with and the wax would remain in the gaps.

Fred

Just wondering what you guys do when you have a 90 degree flange and almost no gap.
Heres an example:



The gap there is almost nil, but gelcoat will still get in there even if its a tenth of a mm.

When I use filleting wax, even the slightest pressure pushes the flange and this happens:



The other issue is that by using filleting wax, i create a radius, losing some definition.

What do you guys do in these situations? |Could I not just skip the filleting wax and hope the release wax seal a gap that small? Thanks