<<As you know from my video, I place the cores in the mylars, then  the 
mylars go inside a release film/breather envelope, this then goes in the  bag. The 
beds are outside the bag. I can't tell for sure from your post, but it  sounds 
as if you might be putting the beds inside the bag or perhaps are not  using 
the top bed at all. If you are not using the top bed and are placing  weights 
directly on top of the vac bag, this could cause dents to appear in the  wing. 
Many years ago I tried putting bricks directly on top of the vac bag  without 
using the top foam bed. The weight of the brick and the uneven surface  of 
the brick caused dents in the top of the wings.>>
 
Hmm, need to look at the breather and bed locations. I've been putting the  
core in the mylars, putting that sandwich in the lower bed, covering with the  
upper breather, then placing this stack on the lower breather in the bag. So 
the  bag contacts breather on both sides but the lower core separates the lower 
mylar  from the breather. The lower breather extends to the vac inlet.
 
The upper bed is used outside the bag and then a very modest weight is  
placed on top of that(3/8" plywood scrap which - just a tad longer than the  
spanwise dimension of the bed). The weight is just to keep the cores flat.  Since 
the defects appear mostly on the upper surface, I've assumed the lower  breather 
was working OK. Maybe that's not a good assumption.
 
Epoxy is well mixed so I don't think that's the problem.
 
<<Too much vacuum on softer foams can cause the entire core to get  
compressed a few thousandths of an inch. It can also cause tips or leading edges  to 
get crushed in odd ways when the mylar extends past the foam and cannot  conform 
readily to the curves.>>
 
I'm not running full vac - maybe about about 20in. The LE and TE are coming  
out fine, even with a bit of overhang from the mylar. Sounds like pressure is  
not likely the problem.
 
Appreciate the comments. We'll go back and do it EXACTLY as in the video  and 
work from there. Maybe it's trapped air that somehow diffuses to the upper  
mylar and gets stuck??
 
- Dave R
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