Sounds like the die is hitting slightly and sliding in with some resistance. Very little though. How's it look with varying driveshaft rotation angles?
I would highly recommend looking into vacuum bagging. I've dipped my toes into the waters a bit on the last few repairs I've done and have been overwhelmed with the finish product compared to normal wet layup. It feels like cheating almost. Next step beyond that is like what @hink320 said...
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