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This morning, I unbagged the layup and peeled off the felt and peel ply. It seems I
had a gap in my peel ply in one small area. The felt stuck.
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I sanded down the sides where the tabs resulted in extra thickness.
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...and sanded the edges to the correct radius for this phase of the layup.
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Time to de-mold this part.
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The base came out no problem.
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Got the center wedge out. An adjacent piece came with it.
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The other small center piece came apart at a glue line when attempting
to remove it. I was able to remove the rest easily enough.
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The end blocks needed a bit of leverage to remove them.
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But in only a minute or two, the part was demolded! W00t!
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My expectation was that these four layers would be .028 thick. Pretty darn close.
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I trimmed the sharp bits off the bottom edge.
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While I was working, Snickers guarded the driveway. :-)
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I then cut the lid and sanded the edges until the sides were .860 high.
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This band is going to be temporarily reused as a spacer for the layup of the next five layers.
I sanded it to a consistent height.
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I reassembled the mold...
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...pressed the lid on the top...
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...and after waxing and spraying the extra band with mold release, pushed it into place.
Tomorrow, I hope to be able to layup the five middle layers. I'm thinking of just wrapping
them around the mold and folding all the tabs up to the top. Also, I need to add a piece
of aluminum on one side to act as the flange of the piano hinge half which will ultimately
be embedded in this lid.
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