So for a while now I've been thinking of the best way to mount my switch panel, this is now the third time I have had a shot something, the first two being timber (carpenter) and me not being happy with the final outcome so then I thought fibreglass might work so here is a little write up. I have never used fibreglass before nor have much of an idea how to do it. All information was gained from you tube and various Internet sites, so feel free to fix me up/correct me but go easy as like I said never done it before.
What I used:
Diggers DIY fibreglass kit 1
Floral foam
Masking tape
Large knife for shaping foam
Tape measure for marking up foam
Black spray paint
Sand paper (p120)
Rubber gloves (used 4 pair as mine weren't correct type for the job)
Scissors
Wax or other releasing agent
*PPE is a must, this stuff smells so a mask is recommended also gloves to protect your hands from the resin mix, ensure its done in an open space also*
Step 1:
First up, using the tape measure and large knife I roughly shaped the floral foam to fit where I wanted the panel to sit.
Once I had a rough shape, using the sand paper I fine tuned it and brought all the edges to sit evenly and make it exactly how I wanted it.
Step 2:
Seeing as I couldn't get the tape to directly stick to the foam, I sprayed it with a coat of fiddly bits black, then covered the entire block with masking tape, to ensure it stuck good I put a couple layers on.
Step 3:
Next up I covered the mould in wax. I don't suggest the wax I used (bee's wax, melted by me. I'll let someone else chime in with other release agents you could use.
Step 4:
Cut the fibreglass to suit, ensuring you cut all the sharp corners so as it will fold over nicely without bubbles.
Step 5:
Read the instructions on the fibreglass kit as to how to mix quantities etc,
It was a warm day so I mixed 1.5ml catalyst with 100ml resin, could have gone a touch more catalyst.
Step 6:
Coat the mould with a layer of the mix. Wrap the mould with pre cut fibreglass. Then using a dabbing motion rather than painting motion, dab the resin mix onto the fibreglass ensuring the entire sheet of fibreglass is wet. Smooth out bubbles as you go and avoid touching the wet fibreglass with your hands as it will pull out fibres.
This is where I'm currently at. I'll have to patch a few areas before removing mould, and add a bit more fibreglass sheeting. I'll add more as i go.
I figure ill put this up now so as that if I have mucked up somewhere I can hopefully be fixed up before its too late.