Fun With Fiberglass

Fiber-Glassing The Body Cast

Here I am mixing up a batch of fiberglass. The directions on the can follow some sort of ratio mixing formula, (so many drops of hardener to so much resin) I however usually just go by color. (the resin I use changes in color when the hardener is added) If you haven't worked with this material before, it may take a batch or two before you can get the hang of it, so start out by mixing small amounts. I recommend that you use a rubber mixing container for the resin. (when it sets up you can just pop it out and start on the next batch)

Now insert a piece of the Cloth into the resin. (once again be sure that you have plenty of Cloth and Mat cut and ready Before hand) I usually lay the piece of Cloth on the surface of the resin (coating one side) then flip it over (covering the other side) then drag each side of the Cloth against the side of the mixing pan. (this will remove any excess resin from the Cloth)

Next, carefully lay the Cloth down into the cast. I like to start from the chest/back area and work my way down. Be sure that you rub, or push out any air bubbles that may become trapped under the layers. (these will weaken the cast)

As you lay in additional pieces, try to overlap them by at least an inch or so.

Here's a shot from another angle. (note that on the edges I have let the Cloth extend over the edge of the cast, this will be trimmed down later)

When laying on the Cloth it helps to start from the upper edges and work your way down.

No matter how thick you desire the final product, you will only need to lay one layer of Cloth over the surface of the cast.

Be sure to spend extra time making sure that the Cloth lays correctly in the groin and armpit areas.

Here is a shot of the completed Cloth layer.

Now its time to lay on the Mat. I've moved the cast into a more open area for ease of access. Apply the Mat in the same fashion as the Cloth. The Mat is a bit thicker, and is designed to absorb and hold lots of resin. (so its a bit more messy)

Once again I start at the neck area and work my way down. (in the background you can see a piece of the "Alien" costume I made in 92', it now serves as a wonderful bug condo)

I will be laying on about 2 layers of Mat, which will give me a good thick, sturdy cast.

Next : Pulling The Fiber-Glass