Originally Posted by GXP_Vince
What takes alot of time the curing of the fiberglass? The reason I am asking is because I plan on doing this as well for my GXP.
Let me get this straight you:
First molded the shape using aluminum foil then spraying it with the foam to keep the shape?
Then took out the whole mold and covered the outside with fiberglass.
Then tryed to get as much aluminum Foil out and the foam out and fiberglassed some more.
When does the supports come into play with that? I would suppose before the second glassing?
Yeah, the longest parts are: the resin mix drying, and sanding the exterior after applying filler.
Yep, aluminum foil. You can skip the foam method since it'* plenty warm outside to lay glass. I did the foam so I could bring it inside, out of the cold, and work on it. If you do the foam method, pull it out, put 1 layer of glass on the outside, pull out the foam and aluminum, and lay the rest of the layers on the inside.
If you just do the aluminum foil with no foam, just lay all of your layers down over the foil. You can use caranuba wax between the foil and the fiberglass so it doesn't stick, but I never do.
I put the dowels in for strength, and not having to do as many layers. Rope works much better, as it will soak up the resin better than the wood will.
Trimmed away excess.
Used dowels to support my MDF speaker ring in place.
Wrapped in a fleece-like fabric. It feels a lot like fleece, and you will find it in the fabric section at Walmart with the fleece, but it'* super stretchy. Be sure to get out ALL
of the wrinkle'* wherever it may be visible. If you do not, you will have TONS of fun trying to cover those later with filler. I also use 3M'* high strength spray glue (like $10-$20/can at Home Depot) to hold the fabric to the box.
After it is wrapped, put a layer of JUST resin into the fabric, no matting.
Now here'* another decision for you to make. If you can reach inside the box and lay the glass from outside-in, do it. It will make doing filler and sanding much easier later. But, if you don't think you can, lay the glass on the outside.
Once your totally done glass, sand it a bit with some rough paper, and start using filler to go to down. Rage Gold is recommended, I'm sure anyone on here that does bodywork knows why. Super easy to sand, works awesome. But... not cheap.
If you get it smooth enough, you can paint. If not, you can carpet it.
BTW, don't cheap out on materials. USC Composites or Evercoat resin works wonderful. Rage Gold for filler, hands down.
Buy plenty of 1" wide brush, cut the bristles to like a half inch stubble. Your just looking to push the resin into the mat, not soak it. Also having the stubble makes it stiff, easier to push out those pesky air bubbles.
Cover your work area! I cannot stress this enough! Wherever you drip the resin, it'* staying there!
Wear gloves! That stuff burns when on the skin! I'd recommend a breathing mask as well if you are working in a closed envirionment. If you have air circulating or are in an open garage, don't worry about it.
Be sure whatever container you choose to put your resin it, make sure it won't eat through. Plasic party cups are a fine example of a bad choice to hold the stuff. It will just eat right through. Paint trays work fine, especially the cheapy'* at Home Depot.
Umm..... I can't think of anything else now. I'm sure I will later. Hopefully this answers a lot of questions. I would also recommend checking out www.fiberglassforums.com
if you are really interested. You would be suprised on the projects some of those guys turn out (custom Ipod docks for computer desks, complete vehicles, etc....).