Fiberglass process...

Our second demonstration and practical was working with fibre glass. This process uses a lot of dangerous and toxic chemicals so it was essential we were kitted out with safety gloves, goggles, apron and breathing mask. We were to use the vacuum formed plastic helmets we had made the previous week to work with fibre glass and create our WW1 military helmets. 

Chopped Strand Mat

Fiber Glass Tissue

1)    Layer a thin amount of mirror glaze over the inner of the helmet mould and repeat process approx x3 leaving 10 minutes between each coat to dry. Once dry, spray with Mould wax release agent (under an extractor) and again leave to dry.

2)    Mix 100g gel coat resin with 1g hardener (a catalyst) and mix with a wooden stirrer till an even consistency. Add a small cup of iron powder to create a metallic effect at the end of the process.

3)    Cover mould in approx. 2mm layer of mixture, ensuring all white areas are covered. Use your brush to spread out and smooth the area so it is even and not lumpy. It will now need 1-2 hours to dry.

4)    Once gel coat resin is dry, coat the first layer of resin onto your mould (only do half at first to avoid areas drying out before you add the chopped strand mat fiber glass). Using your brush dap rather than brush the first layer of the chopped strand fibreglass onto the form adding more resin on top for strength and layering.

5)    Cover all of form ensuring there is an even layer and use your brush to manipulate the strands so they overlap and join.

6)    Once that layer is completed start layering on the glass fiber tissue. This is not for reinforcement but useful for obtaining a good, smooth and safe surface over the chopped strand.

7)    You will now have to leave this for a further few hours till hardened and dried. Your fiber glassed form should be ready for edge trimming and cutting and should hopefully pop out of your plastic mold with a little pressure.

8)    To produce neat and smooth edges use a round sanding mat (make sure to be wearing your mask as the dust produced when sanding is dangerous to inhale.