Fiberglass matting
Fiberglass sheets are fairly thin, and are usually used to wrap around corners and provide a cosmetically appealing finished look. Fiberglass mats, on the other hand, are very thick and are used to add strength. The material itself is, as the name implies, sheets of interwoven glass fibers. Multiple layers are generally used to provide strength and durability. A liquid epoxy resin is applied to the sheets for them to soak up. When this resin has completely hardened, a strong material is formed.
Instructions
1. Prepare the surface you will be laying fiberglass over. If the fiberglass is being directly applied, little preparation is needed. If the surface is very smooth, rough it up with some sand paper to ensure a good bond. Wipe the surface with rubbing alcohol to clean off anything that might prevent good adhesion. If the fiberglass is being formed around an object or a mold, cover the object with aluminum foil and masking tape to prevent it from being damaged. Spray the foil lightly with pan spray, which will work as a mold release.
2. Mix the 2 part epoxy resin in a disposable container, such as a plastic cup. The resin will begin hardening in 5 minutes, so only mix what you will be using at that moment. Stir the two parts together using something disposable, such as a wooden or plastic paint stirrer, since the epoxy coating will be next to impossible to remove.
3. Lay a fiberglass sheet over the object you're working with, and brush on the epoxy resin using a paintbrush. Thoroughly coat the sheet until it is entirely soaked with resin. Using firm pressure, run the roller over the entire sheet to work out any air bubbles or folds in the material. Lay addition layers of fiberglass mats or sheets for added thickness and strength. The number of layers used will depend on your specific project. The layer that will be seen should be a sheet and not a mat, since they look much better.
4. Allow the fiberglass to cure for at least 24 hours before handling it. If you have molded yours around an object, gently remove it at this point, and peel the aluminum foil off to check that the object is still in good condition. The fiberglass part is now ready to be shaped. Always wear clothes that cover your skin, eye protection, gloves, and a breathing respirator when filing or sanding fiberglass. Using a metal file, smooth out the edges to keep them from snagging on things. If there are any contours or openings that need shaped with the file, now is the time to do it.
5. Sand the visible surface of the fiberglass part. Start with a very rough sandpaper, such as 80 grit, to level out the peaks and valleys, then work progressively finer until you reach around 400 grit. Any smoother than this, and the bond between the fiberglass and the paint could be compromised. To prepare the surface for paint, wipe it down with rubbing alcohol. This will remove any loose contaminants that would ruin the finished look.
6. Prime the surface using any automotive primer in a spray can. Hold the nozzle down, and make multiple passes using a side-to-side motion until the entire surface is lightly coated. Allow this coat to dry for about 5 minutes, then apply a second one. Two coats should be enough to provide a paint-ready product. After letting the primer dry for at least one hour, repeat these steps using an automotive-grade spray paint. This may require up to six or seven thin layers to provide complete coverage. Let the final layer dry for several hours before attempting to handle the product.
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