Monday, October 14, 2013

Stage 2 – Harden Paper Base

NOTE: This full tutorial has been moved to my new blog at http://www.otakuandfit.com/stealth-iron-man-mk-vi-cosplay-made-w-fiberglass-and-foam-tutorial/



Stage 2 – Harden Paper Base

FIberglass Back

Fiberglassing the back

Materials I used for this stage:

  • EpoxAmite 100 Laminating Epoxy by Smooth-On

    Epoxy Resin

    Epoxy Resin

  • Fiberglass cloth
  • Chip brushes
  • Disposable cups
  • Organic vapor respirator
  • Disposable gloves
  • Disposable spoons for mixing
  • Dremel
  • 60 grit sanding attachment for dremel

Steps:

  1. Next, I hardened the paper base with EpoxAmite 100 (while wearing gloves and an organic vapor respirator) which is an epoxy resin that is mixed in 2 parts and applied with a chip brush. I prefer using this over polyester resin.

    Top - Resined Piece Bottom - Un-resuned piece

    Top – Resined Piece
    Bottom – No resin piece

  2. I let the resin on paper cure over night to be safe. Once cured, the paper will be a tad bit more stiff, but will require fiberglass reinforcement in order to increase durability. Cut strips of fiberglass cloth, and use the epoxy resin to wet out the area on the inside of each piece to where you will lay the cut pieces of cloth.
  3. I covered the entire surface area of the inside of each piece. Overlapping the outside of the piece is okay.
  4. Once the fiberglass cloth cures over night, I cleaned the stray edges with a dremel with a 60 grit sanding wheel.

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