Initially I planned to use polyester resin for the molds and then epoxy for the flying parts.
I used 5mm foam poster board for my parting planes, hot glued together, designed in the same CAD system and laser cut for an accurate fit.
My first attempt I used Fibreglast water based release agent instead of the tried and trusted wax/ PVA.
I set off laying down a tooling gel coat and multiple layers of chopped strand mat, waiting expectantly to open it up. Shocked when I opened it up that the gel coat had cratered and wrinkled, making the mold useless.
