Just tried my first flat sheet 195g 2x2 c/f, and failed. I am using a polished aluminium table 2.4  x 1.7 Metres, No 8 wax, No 2 resin. I want a single thickness for decoration only. I waxed the Ali sheet and then tried to coat with epoxy, it kept producing pinholes which quickly opened up to bare circles the size of a penny. I brushed it over several times and gradually reduced the number of void circles but clouded the resin here and there, I assume with wax. I did press on and finish the sheet with Vac but had a persistent very slow leak, I just re pumped every 20 mins for 3 hours. The finished sheet (1/2mm thick) also shows tiny voids where the weave crosses. Perhaps I made some schoolboy errors here but a few hints would be much valued. I am wondering if everything was too cold at 12 deg?

Hi,

so if I don't want to buy all the extra stuff can I lay up on easylease, use vac bag straight on top of peelply only, vac till cured, remove peelply, add a coat of resin to smooth out the top, wet flat and varnish to shine?

In theory, just about, yes. However, the amount of work (even if it is free) and the difficulty of the task of applying resin then flatting and polishing up to a smooth shiney finish is so difficult and large that I would really recommend you don't go down this route.

If it's a one-off job and you want to avoid the cost of a catch-pot for example then create a ball of breather in the way of the vacuum line in the bag and so if you have excess resin heading towards your vacuum pump then this ball of breather should hold it off for quite a while. If it comes to the crush and some resin is making its way towards your pump then you can always clamp it off before it gets there. The only other things you need are infusion connectors (a few pounds each), some mesh and some spiral; that's it and you'll be able to make a perfect panel. Use Easy-Lease as your release agent. It's only a little expense and you'll get great results. Doing it the 'hard way' that you describe is pretty much doomed, even though in theory it's possible.

--Matt

Matt Statham
Easy Composites / Carbon Mods - Technical Sales