Remember this project? It's been a while. The plaster took almost a month before it was dry enough to sand. I also got side tracked by several other projects so its time to finish up this mold.

I got the mold face sanded, then used Bondo to fill in the gaps. Bondo is great for a project like this. It's a nice thick putty and, when dry, is easily sandable. I had a minor emergency when I accidentally poked a hole in the bottom of the mold (tip of the cone.) It turns out that the plaster was only about 1/16" thick there. To fix it, I glued a piece of wood to the underside of the mold (to close up the hole.) Then used a healthy application of Bondo to fill / blend it in. Here is the mold ready for a coat of epoxy to seal the surface. The red stuff is the Bondo:

Here is the mold with the epoxy applied.

And here it is after sanding the epoxy and spraying a coat of automotive primer.

If I were really concerned about getting a nice surface finish on the parts that are going to come out of this mold, I would apply more Bondo, then wet sand, re-spray with primer and repeat until the surface was glassy smooth. But these parts are going to be hidden away in the boot of a harness, never really to be seen. The one coat of primer will be enough. I will wet sand this with 600 and maybe 1000 grit sandpaper. Then it will be ready for waxing. I might be able to start laying up my first parts this week.

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