: I can't seem to find the trick to getting the
: glass to lay up close and tight to the mold for the weatherstrip channel.
: After the glass dries, I take a look at it and it's messy, has ragged
: edges around the mold, it's got gaps between the flat section that the
: hatch will rest on and the sides of the weatherstrip channel, and it's
: just plain ugly.

The secret is that you're NOT trying to get the GLASS close and tight to the sacrificial weatherstrip. Rather, you're using thickened epoxy (nearly peanut butter consistency) to fill around the gasket - then apply the layers of glass. In this manner, you're not forcing the glass to make any sudden angles.

: One thing I'm doing that might be a (or the) problem is that after I lay the
: glass on, I'm putting a layer of wax paper between the wet glass and the
: bag-o-sand. Is that causing a problem?

I'd be more prone to use plastic - less likely to get wrinkles in the parting surface material.

I don't think I have any close up pics of the process. I've posted some info about the process in a couple places on my website - the process I used with the Return is noted below. The process on the King has been different but I haven't updated the page, and don't expect to get to it for another month the way things are going.

jrs