For releasing the beam most paste waxes will do. I do prefer a mold release wax, but I have done a lot of mold making and have it on hand. Put the wax on with many layers. I do not put on less than three, but I usually do about 7. Rub the wax on, thinly, let is sit until it starts to dry a bit, then with a soft rag polish it like you would a nice piece of furniture. It will seem as though you are wiping off all the wax you put on but continue this process 7 times if you are patient. It should only take about 10 minutes to complete each layer if it is not raining out. Just have other things to do one or near the boat so you do not rush it too much.

When Mixing the Epoxy with the Silica or MicroFibers leave the hardener out until the end. I do not recommend balloons or too coarsely chopped glass, you need to make sure it will flow and you want something tough. Get the consistancy you like before adding the hardener. It will thin a bit when you do add it.

I put the material in the hull saddle thickest at the bottom and spread it onto the whole area so I am sure there will be connection with the boat. I score the area well with a pick or something that will scratch the surface pretty aggressively. While you insert the crossbar and bolt it down the thickness at the bottom will find its way around the crossbar and ooze out the top and sides. Get ready to scoop this up with something appropriate. Cinch the crossbar down as tight as you would if you were sailing the boat.

Things to consider:

Tape some paper to the sides of the boat under where you are working. This stuff will try to make a mess of things, if you let it.

Make sure you do not trap the crossbar. If you see that filling in the gap completely covers more than 1/2 the bar you can imagine that getting it out will be hard. While working on an Infusion I recognized that this would happen so we were careful to leave an exit for it.

With the right preparation the crossbar with pop right out with a slight tap. I usually can use the palm of my hand and slips right out. If you do not need to take it apart leave it and know that it will come out when you need it. Sometime while sailing you may hear a thud...that may be the bar releasing from the hull.

Later,
Dan