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Old 12-11-2020, 16:13   #16
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Re: Cockpit sole repair question

How to vacuum bag something like this, so long as there is space around the new lip to attach the bag. In this application even a perfect seal isn't required, so long as the vacuum source can keep up with the leaks. Note, all work assumed with epoxy with appropriate temperatures.

Before doing the below, do 1-2 very small layups (like 1 square foot of only 1 ply) at home in controlled conditions to practice, and see how this works out. In particularly, you need to know that you can figure out how to seal the bag, what that takes, and to ensure you can figure out how to draw a vacuum on the bag with your vacuum source.

Basically make a "bag" out of a single piece of clear visqueen/ground cover material (thicker the better). Cut this to size about the lip, as depicted below. Place an air-tight manifold into the bag, somewhere in the middle. Cut layup glass ~precisely to size. Cut peel ply to cover with .5-1 inch extra about each edge of the glass. Cut breather play same size as peel ply.

Then on 'scrap' plastic covering your work table, layup all of your glass plies, followed by a layer of peel-ply, then a breather ply (NO resin in breather ply...it allows air to leak towards the exit manifold, where the peel ply prevents the breather ply from sticking to the glass layup). Then place your "bag" with manifold centered over this. Make wet the overhead where the glass is about to be placed.

Now you need to invert the whole mess, then peel off the 'scrap' plastic, and now you are ready (perhaps with a helper for 5 minutes) to attach your "bag" to the double-sided tape and attach your vacuum.

Voila...everything is in place, but you'll have invariably have air leaks and spend a few minutes sealing that up. Leave the vacuum on 8-12+ hours. After ~ a day, peel off plastic/breather/peel ply and the layup work is done.

Sounds worse than it is. Far less time/work that glassing the top side followed by some amount of fairing and then painting. If you did not bag it...well, I don't know why someone wouldn't bag something like this. Maybe brace it with a pillow or something...which would suck.
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