Pedal Slots
To get straight slots in the bottom and create a durable groove for the pedal levers I cut a piece of wood into strips 3/8" x 20" long. I covered them with wax paper and then tacked them to a board with wax paper on it. Then I cut some thin strips of fiberglass and layed up the channels with four layers of glass and epoxy. The end result was a couple of fiberglass channels that I can bond to the foam.

One unfortunate by product of the slots are the fact that I had to cut through the reinforcing strip of fiberglass that runs across the bottom. If I build another one I'll make sure this reinforcement is further forward. When I do the skin I'll put an extra layer of glass on to make up for the area.



I routed out the foam and epoxy to receive the part.






Bonded in.







The excess will get trimmed off after the voids are filled and fiberglass skin applied.