Join Date: Jul 2008
Location: chesapeake bay
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okay i am not an expert, but what i would do is
first straight epoxy has problems with multible things. first it likes to kick too fast, and its not very strong on its own. thickened epoxy does not like to run out very well, and thinning it so it flows will cause problems in an enclosed space.
i would open the slot about another half inch on the sides, so it measures 1 by 3. then drill a few small holes around the edges where you have it decored, and i mean 1/16 inch holes. basicly drill one every 3/4 to inch around the perimeter.
then get some 6 or 7 oz glass cloth, and rip it apart so it just a bunch of fibers. using what ever tool you can pack this around the edges of the perimeter to a depth of about 1/2 inch. then pack in some unshredded cloth in the hole to fill it. dont pack it so solid it cant move but say a 80 to 90 % fill.
then using card board make a tube that it about 6 inches tall that you can tape over the slot. then mix some normal west system ( or what ever brand ) epoxy, with about 5 % acetone and slow or extra slow hardener, then fill the tube. the weight of the epoxy in the tall tube will help force it down into the glass. you will need to top it off a few times as it works in. if you dont get some very minor seepage out of the small holes, then take a small shop vac and put it over the holes and turn on the vac for a second, until you get some epoxy out of the holes. you could even use a piece of tubing and suck with your mouth. then let it cure for a few days.
after it stops settling you could remove the tube before it cures. i would leave the tube until it cures completely then just cut off the cardboard and epoxy tube.
another option is to pour in the epoxy and use the shop vac on blow and put air pressure on it until it comes out the holes. but i still think the time method of a tall tube would be a more complete fill.