Tue 16 May 2006 |
| Once the plaster-of-paris (PoP) had set off a bit, it was obvious that the two different batches didn't key together very well. Lesson learned - do it in a single batch. After some attempts at recovery, I decided better to start again, so I sawed the mould away and restarted from scratch. | 
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| This time I protected the 'inner core' with some masking tape and marked the edges with blue electrical tape. | 
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| Then a big batch of PoP to get the basic shape. | 
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| Lots of scraping and a bit of rasp file work got the surfaces in roughly the right layout. | 
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| The finish wasn't particularly smooth, so I decided to use clay as a finishing surface - this has the advantage of being workable over a longer period and the PoP seems to help keep the moisture in the clay. | 
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| Then to provide a release boundary I used cling film and prep'd for the fibreglass work. The glass layup went well - using reasonably small triangles of fabric I covered the upper half of the mould. | 
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| As a single piece can't be removed from the plug, I used two lines of electrical tape and continued with the lower half of the mould. Only a few layers of 2oz cloth - I just want to get the shape / prove the principle, then I can bulk it up. | 
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