After cleaning up the bondo from the surface that receives the UND I filled all the mating edges with flox so that any gaps would have proper material in them rather than voids or worse orange bondo pieces. This was all done the day before.

Most of this flox would be later removed. It makes a great surface to layup onto and I ensured everything was smooth as I now really understand the steps involved.

The second pic shows the grey release tape which helps later when removing the plywood forms.

Pic 3 has the 18 plies of UND. The plans say to do this and then 18 plies of BID each side. I decided to do this in two layups and just use peel ply and then the clamps. Just as strong and I’m much more in control of the layup with no chance of things sliding around. I again clamped to keep the plys in place and it squeezes out a little excess epoxy. The clamping pressure was really minimal. Just enough so the clamps stay put.

I also made the clamping blocks a little wider this time and used a spacer on one side which helped. Definitely bigger ears next time I do a similar job.

Flox prep

Release tape

UND layup