Thank you for all the replies! I’m a little overwhelmed and confused but let’s see if I understand this correctly!
@danh - firstly thanks for your reply and all the great info you have on this topic scattered through the site. I’ve searched and read most all of it I reckon! Second, these are gel coated (grey) vans elevator tips. The finish was really good. I’ve just fitted them and contour sanded them. I.e, where they were thicker than the aluminium they were abutting they got sanded down, or the mould lines sanded off etc). This has left some exposed glass and left them deliberately lower than the aluminium edge as per section 5.
My goal is to simply fill the gap against the aluminium edge, and fill the areas where I’ve sanded through the gel coat and into the glass.
I used the word “Pinholes” wrongly I think.
So, from everyone’s replies and the great cozy website link (thank you!) here is my proposed process. Please correct my misunderstandings if you have the time!:
- use a “dry coat” of micro to fill the edge against the aluminium and over any bits where the glass is exposed or where there are any large holes or scratches. (Or do I do it over the whole part??) The consistency is so that it does not run on its own and does not drip off the stick. Squeegee it on quite thick (thicker than the high spots).
-sand this back off to make the edge I want and get the contour I want using a flat sanding board and maybe 80 grit? (Or go finer for micro?)
-once sanded apply a skim coat of raw mixed epoxy, let it go tacky, then another coat.. I will use danh’s method of rolling it on with a foam roller to get the ridges to help in sanding it back off later and not going back down into the micro it glass etc.
-wet sand this with say 180 or 240 on a block?
Have I got an acceptable process do you think?
The only question I don’t get is whether flox would be better to fill the edge against the aluminium skin and also the 1/8” thick section at the front of the counterbalance arms where the skin is curved but the fg part is flat. Can I use flox to fill these edges, sand it back once cured, then micro over the rest of the part as above? Or do the different hardnesses cause issues?
And should I remove the electrical tape and add a few thicknesses of packing tape instead? I really don’t want it to stick and I haven’t tested to see if epoxy sticks to electrical tape.
Thanks for everyone’s time. Apologies if the initial question was confusing or used the wrong terminology. (Apple’s autocorrect changes “pinholes” to “pringles” - a topic I do have ample experience with 🤣