craig wrote:You could use fairing compound to level everything off. Will this even be noticeable under fiberglass (both sides will be glassed)? Unless you are planning on a bright finish, there is no reason to re-cut these panels. Structurally it is fine.
- Craig
Both sides will definitely be glassed. I was more concerned with structure and noticing anything through the paint. After I posted this I did notice a couple of the blogs using fairing compound, so hopefully that will fix anything noticeable through the paint.
You are also right that I am sanding too much. I stated that in my blog. The part that gets me is "greyish color". You can get is smooth quickly, but getting the greyish color takes longer and that's where I get into trouble.
My new plan moving ahead is to give it a quick run over with 80 on the orbital sander and then switched to 120.
Any trouble areas I see, I am switching to the hand block and also using it around edges where I was running into issues.
I will also try not to worry about all the spots like you stated.
My problem with the puzzle joint was it did not want to go together good when glueing, therefore I had to sand to get it smooth. I did another one yesterday and sanded the little fingers slightly before and it turned out ok. I will do that on the remaining puzzle joints. Make sure they fit properly before putting the glue on them.
Thanks again for the advice! Always learning something new, which is fun!