I have just finished my third board using the probox system (two epoxy thrusters and a quad in the 6' range). On all the boards the install has gone great...accept...I always get leakage under the probox jigs when filling in the holes. I glue them down with super 77 adhesive and it seems liek they are all down solid but they ALWAYS leak epoxy under the jig so when I take them off I have to sand down the leaked epoxy. Its not too big of a deal, its just really annoying becuase it would be soo much easier if it didn't happen. How can I make sure the dam between the box and the jig is tight?? Any help would be appreciated. I use the slow cure epoxy by the way.
Lay masking tape on the board first before sticking in the jigs on. Any resin leakage will peel right up with the tape.
The tape also serves as a sanding indicator when grinding down the boxes (if you don't use a ProBox Finishing Router Jig). Grind the box flange down with 60 or 80 grit, when you hit the tape it's time to switch to a higher grit (120) so you don't burn through the glass by mistake.
be careful with the tape, though…if you overlap the tape, you can cause the box to sit proud such that when you go to sand, you actually start taking down the face of the box…which causes your inserts to sit a little high.
this is only for extreme cases where you have two or three overlapped pieces of tape.
you can always exacto out little notches where the guide pins jut out from the box so that they are set on the lam directly.
personally, I only do the first pour with the jig…when I go and do the second pour, I remove them and just pour around the box with a little overflow…seems cleaner to me.
I never thought of that...so you just do the first pour and leave some room...take off the jigs and fill in the rest. Thats pretty cool...do you sand the jig down before filling the rim in or you do fil it in and then sand everything donw? THanks.
doing it this way makes it easier for me to pour in the final batch of resin.
by the time I pull off the jigs, the first pour has hardened and will maintain the alignment.
I don’t have to dam up the surface of the box because I don’t get any in there trying to pull off that tight pour; the jigs are higher than the box walls so overpours invariably go on to the box surface.