Gone to one part at a time. Lowered the complexity level and raised the quality. I am using PVA release agent for this part now. After some research I tried spraying 3 coats of water/detergent mix into the mold first to lower the surface tension and allow the PVA to flow. PVA is thinned 25% water 25% alcohol. Seems to work. Layup is 50gm glass 2mm rohacell core 26gm glass on the inside, a bead of microspheres and a tow of 24K carbon in edges of the flange. Deresined the 50 gm before inserting the rohacell. The 26gm inner surface is a separate operation which makes it easier and cleaner. Electric blanket to cure the resin.