I would insert steam blown (el cheapo) polystyrene foam into the gaps..stick them there if need be and shape back to the rail shape.Laminate, Let it cure and disolve the styrofoam away with acetone or thinners! Viola, simple !
Actually, I know this technique to have been useful in the past, making larger, smooth-faced molds for casting concrete, metals, glass etc. On this build however, the cleanup of the resulting gummy-toxic-goo between those slats would be a nightmare - sticks to everything, and the fumes from this much solvent . . .can't eventhink about it without getting a migrane and my teeth feeling all rubbery.
Another take on this method though that I've found to be a bit more eco- and health friendly is digging out or sand blast removal.
Thanks for jumping in Neal - I appreciate your input.
This is probably just silly, but what about mixing some Rice Crispy’s with Gorilla Glue? Stuff it into the pockets on your rails, let it set, sand it down, and glass over it.
Got the idea from this thread…
http://www2.swaylocks.com/forums/high-performance-foam-blanks-5
OK Swied - you're either A: a stone-cold joker (like myself) B: a guy who started partying a little too early on halloween, or C: Both (again - like myself)
Cheers, and I have to admit, I'm more of a Chex kind of guy!
This may sound too simple, but couldn’t you use the clear packing tape that comes in 2" and 3" rolls and tape over the rails and then lam over that. From there it is a matter of peeling off the glass and then the tape. I think it’s srtong enough to bridge over the gaps. No?
Hey tblank, I’ve tried this a few times since, and have to say that the most simple and direct method is presaturating some glass tape or cut strips and applying directly. Of course, the thread count of the glass being used makes a bit of difference. Sample #3 above was done that way with 6oz glass, with a thread count of 44x31 (http://www.fiberglasssite.com/servlet/the-110/Fiberglass-Cloth-6oz-56"/Detail). Since then I’ve gotten some of their 4oz with a thread count of 60x52. Both are woven so tightly that they’re very difficult to wet completely without a lam roller and warm resin. Once they’re saturated though and squeegeed clean, they won’t let go of that resin.