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After close to 60 hours of making the plugs for the door shells, they finally
had been finished just before turn of the calendar into new year. Making of the
plugs can be found under this <link>
As it was end of December and working in unheated garage it was not certain how
the parts would turn out as the resin would take long time to cure it cured at
all. Never the less decision was made to make the parts as next couple of days
where reasonably warm and hovering in the high single digits during the day and
with the help of a propane heater temperature can be kept close to high teens
and possibly in the low 20's. Preparing the mold by waxing and PVA was very
effortless. However the PVA needed some encouragement drying so that it would
not take a day to dry on its own so with a heat gun it was ready in less then 30
minutes. 12 yards of stranded mat was cut/ripped for the 2 parts and after 3 gallons
of resin and 5 hours laying materials on the plugs the door shells where ready
to cure. Not sure what the cause of it was, was it the cold or was it the
catalyst or proportions. The resin was not setting up and was gravitating to the
bottom and pooling at bottom of the shells. Eventually it did cured however it
took 2 days to do so. All that we can think of was possibly temperature
inside the garage. The parts where left sitting for close to 3 weeks just
to make sure they had cured and would not warp over time.
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