Why did this take 8 hours? …. crazy. This is glassing the top outside portion of the sump lid. I was going to do a glass to glass on this which meant routing the .8″ of foam off the top where the hatch goes but after some thought decided that it would be stronger to leave half the foam and do a careful flox corner to seal the remaining half later.

Pic 1 and a tried really hard to make a perfect route down to the .4″ level. You can see there are a couple of excursions into the foam that were unplanned. So much for perfection eh?

Pic 2 and its very nice now. I used 60 grit then 80 and 120 to get the best surface I reasonably could. That took some time but as you can see a good result as surface prep for the subsequent glassing.

Pic 3 and I have micro then two plis of BID and some peel ply where there will later be bonding. Its late at night now and I will still be wandering out to push the glass down in those lowered areas in the hope of a bubble free result. I did end up using the special fuel safe epoxy on this. I thought about just using it around the open port area but decided to go whole hog. If I am only 50 grams short for the whole job when I do the strakes… that would be most unlucky.

Careful routing

After a long cleanup

Two ply of BID