ikester

Old thread, but a fiberglassing trick i learned when building a full scale Lancair plane might apply: On bench, lay down some clear plastic, maybe two mils or so thick (I forget). Place dry fiberglass cloth on the plastic. Pour on some epoxy resin, do not try to spread it. Lay down another sheet of plastic over the epoxy, making a plastic -> cloth -> epoxy -> plastic sandwich. Use a roller to smooth out the sandwich and evenly distribute the epoxy over the fiberglass. Roll with enough pressure to force excess epoxy out and away from the fiberglass to save weight. The plastic sheeting should be larger than the cloth piece to catch the excess epoxy...6" or more along the entire perimeter or so. Using a rotary cutter (looks like a pizza cutter), cut the sandwich a bit oversize to fit the part you want to cover. Remove one of the plastic sheets and lay the fiberglass on the part to be covered. Using a stippling brush (cheap disposable paintbrush with bristles cut down to about 1/4 inch or so), dab the cloth into the part to be covered. When satisfied that everything is making contact with the part, slowly and carefully lift the plastic glass off the part. You probably need to dab at the glass some more. Let everything cure. This method worked well for me, since it minimizes the fiberglass cloth distortion and leads to good adhesion with minimal epoxy remaining on the covered part.