OK, so I've had a lot of request with people trying to build ther own stuff ...so I dispence some info here for all to see and hopefully it's gonna lead you inb the right direction.
First thing you have to know is that in TODAYS day and age fibreglass and resin are not the leading standard in composites, it is an old system....But it's the cheapest and easiest system to learn. All none structural peices and panels can be made with Polyster resin,MEKP catalyst and a conbination of mat and roving fibre glass. Gel coat is recomended as a pre-surfacer. It makes finished surface easies to paint as it is paint compliant. Make sure to use finish (or waxed) gel and NOT TOOLING GEL. Vinyl ester resin is used in making gas tanks and fuel cells. Try to stay away from using Vinyl ester, it is very expensive and has a short life time uncatalized. MEKP catalyst (Methyl Ethyl Ketone Peroxide) is the catalyst added to polyester resins and vinyl ester resins. As the catalyst mixes with the resin, a chemical reaction occurs, creating heat which cures (hardens) the resin. Use approximately 1/2 oz per quart of resin. There are 3 stages to resin,
1st stage is the wet stage, that is when you mix the resiin and catalyst together. Your work time is about 10-15 min at about 15 deg C. A common mistake to all new comers is that they tend to try to wet the glass and work with it immidiatly.RELAX IT'S NOT GOING ANYWHERE. Saturate the glass and let it sit for about 1 min. , then go back and start rolloing it into shape. You'll notice that it is way easyier to work with, that's because the Ketone in the Catalyst has broken down the binding powder that holds the mat fibres together.
2nd stage is the gel stage. You will notice that the resin is starting to get a hard and quite warm. At this point you should take a sharp Knife and cut off all the excess materials hanging over the mold ends. This will save you from grinding and sanding it down when the glass has hardened, Unless you prefer itching and scratching for the next few days.
The last stage is the Hardened stage ...NOT THE CURED STAGE...That's because all resin takes up to 6 months to CURE. Expect to have about 2%- 3.5% shrinkage in all peices.
Make shure that your molds are well waxed. I recommend that your mold surface is a 1500 grit finish with 5-7 layers of mold release wax applied every 1 hour and buffed between every coat.
OK that's it for this session.
Maybe Iggy Claus will give you a MOLD MAKING how to next week.