If you want to make a "professional" mold easily try this; 1. Your master is perfect. 2. Your master has a hard finish like catalyzed polyester paint or urethane and a high polish. 3. Make a splitter board. Add locating balls or pins and bushings to the flange. 4. Make a Steel frame of 1 X 2 welded around the perimeter of the plug offset by 2.00" 5. Use a good carnauba release wax, wax and buff. Let cure and repeat 4x. 6. Use Epoxy gelcoat. Add about .025 thick and even coverage. Apply with a 1/2 brush and start from one end always keeping a wet edge. 7. Mix thick (like mayonnaise) slurry of epoxy and milled fibers and attach the clean, sanded frame to the gelcoat. 8. Now the fun part. Mix a slow cure epoxy laminating resin with clean white sand. The kind used in ash trays. You can buy at the tile store. Mix the slurry until you can't add any more sand to solution. 9. Pack the sand over the gel coat while the gel coat leaves a finger print but does not come off to your finger. Pack a mix about 1.5" thick. 10. Let cure for 2 days and flip over and repeat the process. The mold is only as good as the master; the edge and parting line are only as good as the splitter. Take your time on the master and splitter. It pays off in the end 100 fold. It will take less than a gallon of resin to make a 55 glider fuselage mold. US Composites seams easy to buy from. I havent shopped there so I dont know first hand. Tom Copp Composite Specialties www.f3x.com 949-645-7032
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