Mold Construction
After prepping the piece to get it as smooth as possible, I've make a wooden template to create a seamed mold. This will be a 2-piece mold. The plywood creates a flange that will accept another matching flange when the front side of the mold is created. The plug has been sprayed with a few coats of PVA, mold release. The next step will be a couple coats of tooling gel coat. I'll use orange to see that I've covered everything uniformly. Normally I'd spray the gel coat, but this piece is small enough that I can brush it on easily and quickly.
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