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This video will show the construction of Vectus Racer mold in polyester resin.
To make the mold, you need a good model, called the plug.
In this case the plug is made of wood and fiberglass, coated with PU paint.
The mold comprises two halves, then it is necessary to divide the plug somehow.
For this, I made a wooden platform where the plug is firmly supported.
I used 9mm MDF, because the platform must support the weight without yielding of the steel structure that will give mold resistance.
This is important to prevent it from warping with temperature changes.
I used sheets of 3mm thick cut in the shape of the plug into several pieces.
These sheets, which are called ***, were placed on the platform.
How fitting the wood will never be perfect, I used epoxy to the junction with the plug.
Another way is to use modeling clay.
What matters is that the seam is perfect and the gelcoat will not run through it.
I used microspheres with epoxy along the seam and then fit the plug.
Recalling that the plug was already waxed and with a thick layer of PVA.
This is done across the boundary and after the resin cured, the excesses are sanded.
So we got a perfectly shaped *** on the plug, splitting it right down the middle.
Then, I did a containment barrier that will prevent the flow of gelcoat and will form the side of the mold.
Hence we apply the PVA with a pistol. Seeking to apply about three layers at least.
And use the hair dryer to dry well between one coat and another.
And finally it's time to apply the gelcoat.
I often use 2 or 3 layers.
The important thing at this time is to AVOID getting air bubbles trapped. Therefore you should not use much catalyst.
Once started the lamination, do not stop, because there must be a chemical bond between the layers.
This valve was placed to help loosen the plug with compressed air.
Multiple layers of fiber glass fabric are applied.
The first layer is a thin fabric, then increasing the weight of the fabric.
The thin fabric fits the shape of the plug, avoiding air bubbles.
With a brush the air is removed.
Finally, a thick layer of fiberglass mat.
And the next morning, the first half is ready and excesses are removed.
Then the second half is laminated in the same way. The plug must NOT be removed before that!
And the halves are separated.
Thanks for watching!