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After curing overnight, it was time to remove the lid from the mold. Given all the difficulties
experienced during the layup yesterday, I didn't have high hopes. I peeled both bags and the
(failed) plastic overwrap off.
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Then pulled out the felt and peel ply. Apparently I missed a spot with peel ply and the
felt stuck.
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I removed the sides...
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...then pulled the part out. Unfortunately it looks like my carefully created fillets
of wood filler didn't stick to the mold...they came out with the part.
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I used some acetone and a putty knife to scrape as much of the filler off.
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After sanding the corner radii I tried in position. Even though the layup process was
a train wreck, the end result isn't terrible. It is *way* better than the last lid.
However, having thought this through last night, I decided that, now that I am able to do
vacuum bagging, the greatest problem is the fact that I'm using a female mold. So,
I'm going to go with a male mold instead.
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Since I want the outside dimensions of the part to be very tightly controlled, I'm going to
do a test layup to see how much each layer contributes to the final thickness. I pre-pregged
a scrap piece of fiberglass.
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And laid out some test sample squares.
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With the squares cut out...
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I built up a sample that was six layers thick...
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...covered it with peel ply...
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...then bagged it up with some felt.
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With the vacuum line attached, I still had a small leak.
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Instead of fighting with it, I just decided to bag it in a garbage bag like last night.
That resolved any leak issues. I'll measure the stackup thickness in the morning.
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