Thanks for the heads up at Ace. I love my neighborhood Ace store. While they may not be a true chandlery, it is the only place around here to find 5200 or a decent assortment of stainless fasteners.
Mike,
Well, the vacuum pump was a complete wash...We applied the K.I.S.S. principle and it worked just fine. It was like sand casting, sort of, and upside down.
I taped the mold with packing tape, being the PVA turned out to be a PIA, then stapled the matt in place to keep it from sliding out of place. The matt was heavily wetted and a layer of FG fabric was worked down over the top. Cover the mess with lightweight plastic wrap and pack it six inches of sand.
After about four hours I dug it out and put some filler on the back and added some styro pieces for build up and waited another hour or two. When it got to a real tacky state, I wetted out some more matt and covered the back again. By night fall it was ready to come off the mold.
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