Everything going smoothly, then a second of inattention. Realized too late that I had not seated the router collar completely into the jig plate and it went wandering-
Any advice for a fix?
Build a dam and fill the void before pasting in the box?
Paste in the box and fill the void at the same time?
TIA
What could I do to make the void least noticeable, match the foam as much as possible?
Slap some lightweight spackle; patch n paint or fast and final, in that beeyotch. Done. I’d leave it just like you have it pictured, take the spakle and roll it in my palm into a ball until it’s all nice and compacted, smush it into that gap, take some wax paper and a squeegie so I really don’t need to sand it later across the top, let it dry a little bit then gently pull the box out, let it dry and sand where I had too. I’ve seen that happen a few times:) No biggie. Def. don’t fill that big gap with resin!!! Just don’t try to paint and hide it. IF it were somewhere else it’s a “place logo here” spot. Next time save that choice piece of the white widow 'till you’re all Pau… JUST KIDDING.
I mixed up a small batch of resin with a small amount of white pigment and added glass fibers until it was a thick paste. I filled the booboo and used the Futures jig and router to clean up the opening once the resin set up. It was almost invisible once the board was glassed, but I wouldn’t try to paint the blank or tint the glass job over the repair.
BTW- your other boxes seem to be sitting kind of high. They should be routed in deeper.