Resin infusing a SageCat deck

The first production SageCat is being assembled.  Last week the new deck mold was completed and now the first deck has been made.

Here are some pictures of the deck being prepared for resin infusion


The deck mold has been buffed, sealed and treated with mold release.  It is now ready for gel coat.


A ‘skin coat’ of fiberglass mat is applied to stabilize the gel coat and limit any fiberglass print-through.


Over the structural fiberglass and balsa core peel ply is placed to assure the flow media comes off the part. Flow media assures the entire deck structure receives the correct amount of vinylester resin.


Over the flow media the vacuum bag is placed.  The vacuum pump is the machine in the lower-right of the picture.

Vacuum is applied to check that there are no leaks in the bag.   If no leaks the resin is mixed and the part is infused –


A 5-gallon bucket holds the vinylester resin that is ‘sucked’ into the deck mold.

Here is a quick video shows a portion of the SageCat deck being risen infused –

After the part has been fully infused the vacuum bag and infusion media are removed.  The interior side of the deck is now prepped for gel coat –


The deck after the infusion bag and flow media are removed.


Here you can see some of the flow media after being peeled off the deck.


Deck interior side has been prepped and is now ready for gel coat.

Now the deck interior finish is sprayed –


Wearing a ‘bunny suit’ Matt safety sprays gel coat in the spray booth.


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