I
marked up the wing bolt access holes per plan. It consists of three (3)
rectangular rings. The inner most is the 5"x13" rectangular ring for
the cut out. The middle one, which is about 1/4" wider, is for glass to
glass joint. Lastly, the outer most ring which is 1/2" wider than the
middle ring, where the foam starts to slope
towards the cut out hole.
I used the FEIN tool to do a rough cutout (inner ring), then I used a Dremel (with a vertical holding fixture and sanding disc) and trim the edges all the way up to the inner ring. Then I raised the height of the sanding disc to just above the underlying glass surface and removed the foam up to the middle ring. Lastly, I remove the Dremel out of the vertical holding fixture to form the slope between the outer rind and the middle ring.
If you have done the UNI lay-ups in previous sessions, this one is duck soup. Just need a bit of poking and shuffling to get the UNI to lay down nicely along the beveled edges around the access holes. The width of the UNI strips that I pre-cut were 10 1/2" wide. It needs 3+ strips per layer. Don't forget to round off the edges before the lay-ups and alternating the UNI layers.
I did the end lay-ups first because I did not have a 2 1/4" hole saw. I used a Dremel and a stone bit and trimmed a small flox trough all the way around the out board bulkheads. Lay-up 1 layer of BID and trimmed the edges after cure.
I
got a 2 1/4" hole saw from Lowe's and put the holes in without any
problems. Then I removed a bit of foam inside the hole by rubbing it with a
scrap piece of similar foam. Then I applied dry micro and smooth out with a stir
stick.
Once cured, I sand the micro down with find sand paper so that it is nice and smooth.