Several days, yes days!!! …were spent getting my head around cutting the BID and placing it correctly in this U shaped foam box. It was very tricky and I may even have learned something.

For a job this challenging it needs to be on the dry prepared surface and then add the resin. It is far too difficult to lay this up on wet micro and have things work out. As it was it was still a very tough layup and a few minor fixes will probably be needed after cure.

In the first pic you can see the glass in position and a few weights to hold the edges. I did put down some tape to protect the bare glass at the tops of the sides.

I took nearly 5 hours just doing this inside one ply layup. I’ll definitely get Darren in next time for this size job. I purposely worked from one end as it was pretty much cured by the time I was at the other end. Then I had to lay down myself for a while.

I would have liked to get the glass stippled out and squeegeed more but I had to work with the cure time and the fact that as you play with the glass it goes all over the place so it was ‘careful fiddling’

The important part of this job is getting the hard point layups spot on and I will have the time to do this given I’m not going per plans with the schedule. My method will give a better result for my speed of working. This one ply layup is not at all critical in that its just holding the box together really. I have still tried very hard to do the best I can and it sure has taken a while for this small step.

Positioning the glass

Wet layup

Inside 1 ply BID