Before we bonded the foam the curved pieces had to be thermoformed to fit the lower edge. Duct tape held them in place until they cooled down. Once cool all the pieces were numbered and removed. Then the core putty was troweled on, the core was primed with hot priming resin and pressed into the putty. Not unlike tiling the bathroom.
To develop the upper radii we used a shaper to bull nose a strip of core and then bonded it in place.
Once the putty went hard all the cracks were filled and faired.
Prior to overlaying with the final laminate a sealing coat of hot resin is applied and allowed to cure.
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