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To cast a fiberglass part from a mold, Andy uses 1708 biaxial fabric and 2-to-1 epoxy resin, prioritizing the epoxy’s longer working time over the faster-curing polyester resin.▶ 8:15 To prevent the fabric from shifting during the initial layup, he lays the dry 1708 directly onto the PVA-coated mold before saturating it with epoxy, rather than wetting the mold surface first.▶ 13:10 He manages complex corners by cutting slits in the fabric to allow for overlapping pleats.▶ 15:09 As a precaution against the part bonding to the mold, he drills four holes in the corners of the mold to allow for the injection of compressed air during extraction.▶ 16:17 After the layup cures, he uses water to dissolve the water-soluble PVA at the edges and compressed air through the drilled holes to successfully separate the part.▶ 21:03 While the exterior surface shows air voids, these are confined to the sacrificial first layer and can be sanded and filled.▶ 19:34

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