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Old Oct 28, 2011, 08:21 PM
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Shaper Dave's Avatar
Oahu Hawaii
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Well, its one week later and the mold has been opened! Just as I expected, an excellent mold.
In the photos you can see its been all trimmed up and all the nasty little pokey strands have been rounded off so its safe to grab.

Once you have started the separation in one corner, stir sticks are the tool of choice. Sliding them down the flanges, going slow you can see the diagonal line of the release as you go.

Everything was clean and the TE fence was removed. Now some 1000 grit and polish it up.

Now onto the P5 molds.

Dave
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Old Oct 28, 2011, 10:58 PM
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1900 Driver's Avatar
Denver CO
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Looks awesome!! doesnt look like much polishing is needed!

Brandon
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Old Oct 28, 2011, 11:29 PM
Aurora Builder
United States, MD, Lusby
Joined Nov 2003
3,408 Posts
Polishing, what polishing? That surface finish is IMMACULATE! Really nice work!
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Old Oct 28, 2011, 11:50 PM
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Thanks guys,

There is a micro texture from the PVA that needs smoothing and the edges need to be flattened around the leading and trailing edges. Light work but the main thing is there are no ripples or bumps to straighten out.

Dave
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Old Oct 29, 2011, 12:00 AM
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Cody, WY
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Quote:
Originally Posted by Shaper Dave View Post
Thanks guys,

There is a micro texture from the PVA that needs smoothing and the edges need to be flattened around the leading and trailing edges. Light work but the main thing is there are no ripples or bumps to straighten out.

Dave
Looks awesome, Dave.

Have you thought about trying some other release systems that will mimic the surface on the plug? In my experience it's much easier to polish painted plugs than it is to polish molds.
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Old Oct 29, 2011, 12:17 AM
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San Gabriel Valley, CA
Joined Mar 2008
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Originally Posted by Shaper Dave View Post
...
Now onto the P5 molds.

Dave
Noooo You can't stop here! I thought we are going to see the Ghost in Halloween

Tai
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Old Oct 29, 2011, 01:20 AM
Chesty
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Reedy Creek, Qld, Australia.
Joined May 2003
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Shaper Dave, you blow my mind !!!
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Old Oct 29, 2011, 02:30 AM
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Oahu Hawaii
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Adam,

I used to spend crazy time making the plugs completely scratch free and use only wax as the release. I found that I still had some sanding to do on the edges and maybe something stuck and I had to fix it etc.

My system has been worked out over many years and the results are always good. The key for me is a very thin PVA coat as an aid to the release. Not a full barrier as normally done to stop the resin from touching the surface. Its still 10 coats of Mold Wax then the mist coat.
Sanding the texture is minimal work for me, most people would not notice the texture if they look at the mold.

For me I know there are other systems and I always read what your doing as well. Great stuff by the way.

Dave
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Old Oct 29, 2011, 11:10 AM
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Cody, WY
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Originally Posted by Shaper Dave View Post
My system has been worked out over many years and the results are always good. The key for me is a very thin PVA coat as an aid to the release. Not a full barrier as normally done to stop the resin from touching the surface. Its still 10 coats of Mold Wax then the mist coat.
Sanding the texture is minimal work for me, most people would not notice the texture if they look at the mold.
Press on. I just wasn't sure if you new of some other alternatives. I'm Frekote to the core when making molds.
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Old Oct 29, 2011, 04:38 PM
M Seid
Solana Beach, Ca
Joined Sep 2006
2,947 Posts
Dave, wheres the order form form for a new sd winter board. Think 6 foot Swamis, from the nnw. Do I really have to buy freaking retail? I don't care which winter you deliver it either. 2012/13 is fine, and I'll even head over there to pick it up.
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Old Oct 29, 2011, 05:10 PM
Entropy is happening!
Jim.Thompson's Avatar
Bellingen NSW Australia
Joined Aug 2008
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Vac bagging wing plug/hand layup comparison.

I have just checked my vac bagged wing plugs for accuracy with a template printed out from Profili. At the root, my wings are 260mm chord. They are compressed at least 1 mm. at the point of maximum thickness! (maybe closer to 2 mm!)
This is further validation in my mind of your method of hand layup of the glass/carbon without vacuum Dave!
I will be doing any future plugs your method. ie. without vacuum.

Jim.
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Last edited by Jim.Thompson; Oct 29, 2011 at 05:12 PM. Reason: correction of italics
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Old Oct 29, 2011, 05:41 PM
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Oahu Hawaii
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Mike,

After I help my friend Carl Schaper get his shop going out at the Sugar Mill in Waialua, I may get to put some stock boards in his show room and do some custom boards as well. My speciality is Fun Boards, Long Boards and Vintage Short Boards. We'll talk.

Dave
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Old Oct 30, 2011, 07:59 PM
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Oahu Hawaii
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Jim,

You don't need to use full vacuum doing a plug. You only need to go no more than 8-10 hg for plenty of contact.
If your using the Dow Blue foam called "square edge" that I get here, we know it as a 2 lb foam density. Im surprised you would have that kind of change in the foil. I normally use 22-25 hg with normal bagged wings and no change in the foil size. This makes me think your using a lighter weight foam.

Dave
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Old Oct 30, 2011, 09:12 PM
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Cody, WY
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Originally Posted by Jimbello View Post
I have just checked my vac bagged wing plugs for accuracy with a template printed out from Profili. At the root, my wings are 260mm chord. They are compressed at least 1 mm. at the point of maximum thickness! (maybe closer to 2 mm!)
This is further validation in my mind of your method of hand layup of the glass/carbon without vacuum Dave!
I will be doing any future plugs your method. ie. without vacuum.

Jim.
Did you mic your cores before bagging to make sure that they were correct to begin with?
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Old Oct 30, 2011, 09:46 PM
Entropy is happening!
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Bellingen NSW Australia
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Originally Posted by wyowindworks View Post
Did you mic your cores before bagging to make sure that they were correct to begin with?
No Adam. And because of that I cannot say for sure where or when the error was introduced.
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