I have a piece of aluminum i am using for a plug. It is 1/8" thick mostly flat with like 15 holes drilled thru it. The holes are 7/16" diameter.
How would you go about filling in these holes so the plug surface will be perfectly smooth?
bump bump
does your surface need to remain aluminum? I would probally put fiberglass patches on the back side, and use filler to fill the holes, then duratek the surface and buff
Oil based modeling clay.
I just thought of this, so I dont know how well it will work. but try taping the back side and melting wax in to the holes, then trim them down and use a heat gun to smooth out again…could work good.
I’ll try the wax or clay.
I think if you do the clay it will show up on your mold, but worse you would have to do is wet sand and buff. I dont know how well the wax idea will work, but probally worth a shot
Out of curioustiy are you going to need to re-drill the holes on your finished part?
If you just need a register on the mould so holes can be drilled in final parts, then why not just put registers on the plug?
I’m guessing that it’s a foot guard for a motorcycle, so although the original has holes (for lightness), the carbon part just needs to be a basic flat guard.