Fiberglass is a very durable and lightweight construction material that is used for many different applications. Some common applications for fiberglass are pools, industrial pipe systems, tanks, walls, boats, and duct work. Fiberglass is made up of dry fiberglass mat that is saturated with catalyzed fiberglass resin. The mat is applied in layers with a lamination process. The more layers of mat that are added the thicker the fiberglass will be. All fiberglass materials can be found at your local marine supply store.
Instructions
1. Prepare the surface of the table you will be laying up the fiberglass on. Use a seamless table that is bigger than the wall you will be making by at least three inches all the way around. If the table is not metal cover it with a layer of mylar. Spray the surface with spray glue and apply the mylar. Use a squeegee to get the mylar completely flat with no air bubbles.
2. Apply two coats of boat wax to the mylar and buff it out with an electric buffer.
3. Cut the fiberglass mat to size using a razor knife. Cut the mat two inches bigger than the dimensions of the wall. This will give room for error. Cut as many layers as needed to achieve the correct thickness for the wall.
4. Mix the catalyst into the fiberglass resin using the recommendations on the containers. Use a bucket and a stir stick to mix the resin thoroughly. When the resin is one solid color it is ready for application.
5. Wet the entire surface of the table with the resin mixture using a felt roller. Apply the first layer of mat and saturate it with resin until it is the color of the resin. Roll out all the air bubbles in the mat using an air roller. Apply the rest of the layers using the same process. Let the fiberglass harden. If the wall is extra thick, lay up the half of the layers of mat and let them harden. After the first half is hard and cooled down apply the rest of the layers. This will prevent the fiberglass from warping from getting too hot.
6. Pry the sheet of fiberglass from the table using a flat pry bar. Once it's off the table mark the dimensions of the wall using a large square and a wax pencil. Once you have the outline of the wall, measure from corner to corner on both sides and if the measurements are the same the wall is square. If your marks are not square wipe them off and remark the fiberglass.
7. Put on a respirator and cut the wall out using an electric right angle grinder with a fiberglass blade.
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