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Hi Tim,
To solve your flange issue, in an ideal world I'd say lift the plug off the body (if stiffenough) so you have unrestricted access all round. However, this may not be as practical or easy as it sounds in some cases!!!
However, if you can't do that, its not the end of the world. You just have to go back to think of the purpose of the flange where you have located it. For most processes a small flange of sorts is necessary to give a neat edge to the part so you can trim it and also it helps prevent mechanical lock. For vacuum processes, it is a little more important as the flange is often also used as the bagging flange and you would need the space to fit the bagging stack so it seals well to the mould flange. Extra space is particularly important on the vacuum port areas and the resin feed side of the mould.
So not withstanding that, you can be quite creative with fluted signboard when making flanges so you just have to do it the best you can where things are tight.
Warren Penalver Easy Composites / Carbon Mods - Technical Support Assistant
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