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

Looks awesome!! doesnt look like much polishing is needed!

Brandon

Polishing, what polishing? That surface finish is IMMACULATE! Really nice work!

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

Originally Posted by Shaper Dave

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.

Originally Posted by Shaper Dave

...
Now onto the P5 molds.

Dave

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

Tai

Shaper Dave, you blow my mind !!!

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

Originally Posted by Shaper Dave

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.

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.

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.

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

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

Originally Posted by Jimbello

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?

Originally Posted by wyowindworks

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.