foam-n-fibre wrote:Hey Dany, I think if you use peel ply you will always have a dull and slightly rough finish. Yes, you get good excess resin removal, but then you have to add more resin after to get it smooth, and sand and polish. If you go with the method of vinyl on top of the glass and cotton, and squeegee as much excess out as you can once the vinyl is on top, you will get a pretty smooth and shiney finish. I'd be surprised if you could tell the difference in board weight, and there's no risk of sanding into the fibers and weakening it. (the vinyl method is what I use in my youtube video, but I can't claim to be the inventor of that)
As for the plexi, yes, you can scrape it with something plastic, like maybe try the edge of an old credit card. From what I hear, some epoxy will not bond well to plexiglass and other stuff will, depending on how they treat the surface of the plexiglass when they make it. On other plexiglass types, epoxy might bond too well making it tough to pull off the board. You may find that future jobs on the same plexiglass begin to bond better and better, and it will then get harder and harder to clean the plexi without scratching it, so you might want to use some release for future boards. If you're up this way I can set you up with some.
(edit) - I should also add that yes, sanding and painting CAN look very professional, but it can also look awful if not done well. For most of us, I think you can get as good or better finish results without nearly as much effort using vinyl over the glass as the top half of the bag. A cotton topsheet compared to pigment adds 100 to 150 grams. Not sure how much paint weighs, but it's not a huge weight saving.
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