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

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.

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