10 adding deck core

May 15, 2021

Wet out all glass on table, with carbon and E-glass support patches underneath a full layer of cloth.
Roll full glass sheet on to carboard roll and set aside.
Roll resin in approx 2" strip around the bottom of the board. (Will help stick down the fiberglass in next steps).
Flip the board over so the deck is facing up.
Place, smooth out all support patches on deck.
Roll full glass sheet on top of everything, smoothing it around the the underside of the board.
Add core material on top. Tape down core material to hold in place.
Put board in vacuum bag with deck side down. Pause the vacuum pump before it reaches full pressure and smoothing the bag and core material around the rails toward the center of the board will help to ensure the core material is firmly adhering to the board.
Apply full pressure, and leave to set.
Remove the board from the bag.
Sand off the bottom lap-over of core material. Fill dart areas with epoxy-micro sphere mixture as necessary.

I found this to be by far the most difficult step. There were a lot of steps to do before the epoxy started to cure.
It was helpful to have a brush to push the fiberglass in place on the bottom side of the board.