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Posted: **Sun Aug 14, 2011 2:16 am**

Making Fiberglass Molds, Fiberglass Parts and Vacuum Bagging

I think fiberglass is the oldest technique to make parts with and has been used for years for making helmets and armor parts. This thread will be dedicated to making fiberglass molds and parts.

Again I am no expert but I do have a little experience with this topic as we have made several fiberglass aircraft and have used many of the techniques to make them. we will cover making the plugs ,ridged molds, making parts with sandwich techniques and vacuum bagging. Book recomendations, industry links, feature builds of other modelers, How to Videos and tutorials, Materials (Glass fabric, Carbon Fabric, resins, gel coat, painting in the mold, fillers and dyes), and anything else I can find on this subject. so please jump in with any info you can contribute.

as always I will edit and tweek my posts as we go. Please try to stay on topic.

Just like the other methods, Vacuum Forming, Resin Casting, Rotoforming, A great final part starts with a great master plug.

Fiberglass is just one type of fabric that can be impregnated with resin in a mold to make parts. You can also use carbon fiber, Kevlar, Nylon, and a lot of other materials. but we will start with the books and the glass cloth first.

Alot of the mold making information from Resin Casting and Vacuum forming are used here as well with some variants.

Most of the Resin Casting molds are silicone and here we will be making hard ridgid molds to lay up the fiberglass.

Sandwich Fabrication is a method used to combine several layers of glass, carbon, wood, paper, cardboad or other materials to achive your desired part.

Vacuum Bagging is a process you use once you have layed your cloth and resin in your mold. The Vacuum Bag removes all of the air and bubbles from your part, compresses the fabric and resin, makes an even distribution and makes very smooth parts.

Posted: **Sun Aug 14, 2011 3:18 am**

Fiberglass Books

Let's start with some must have books. Like every other subject worth learning, you have to wade through the ocean of books on the subject and very few have the info your looking for so let's cut to some pretty good books that I think are the best for getting started on fiberglassing parts. Alot of books on this subject are geared for making Kyacks and boat fiberglassing, automotive and so on, so we need to weed through the mess and get to the Mold and part making stuff.

Composite Basics, Seventh Edition

By Andrew Marshall, 2001, approx. 150 pages
Anything but basic! This book begins with a simple discussion of fabrics and resins but continues through sandwich core structures and engineering with the materials. Stress testing and load analysis are also covered.

[attachment=0]Fiberglass and Composite Handbook.jpg[/attachment]

This book is $39.95 and is available here at Fibre Glast (Composite Basics 7th Ed.)

This book will get you familiar with the different cloth types, sizes, thicknesses, weaves, resins and so on, I don't think stress and loads are really important here but you never know?

Posted: **Sun Aug 14, 2011 3:31 am**

Books Cont.

Composite Materials Fabrication Handbook #1

By John Wanberg, 2009, 144 Pages
The "Handbook of Composite Fabrication" covers all of the major composite manufacturing processes in a single, concise volume. Perfect for all levels from beginners to experienced.

[attachment=0]Composite Materials Fabrication Manual #1.jpg[/attachment]

While most books on composites approach the subject from a very technical standpoint, this book presents practical, hands-on information about these versatile materials. From explanations of what a composite is, to demonstrations on how to actually utilize them in various projects, this book provides a simple, concise perspective on molding and finishing techniques. Composite Materials Fabrication Handbook includes shop set up, design and a number of hands-on start-to-finish projects documented with abundant photographs.

Chapter List:

Posted: **Sun Aug 14, 2011 3:46 am**

Books Cont. 2

Composite Materials Fabrication Handbook #2

By John Wanberg, 2010, 144 Pages

Composites Fabrication Handbook #2 is written for those who want to enhance the quality and performance of their composite projects. Learn what it takes to truly optimize a composite lamination for high-performance use. Basic mold making is covered in this book to help fabricators produce effective mold systems from a variety of molding materials. Several advanced molding techniques are demonstrated in-depth, including vacuum bagging, trapped-rubber insert molding, inflatable bladder molding, or resin transfer molding techniques. In the spirit of Composites Fabrication Handbook #1, this book presents each subject in a hands-on, practical way.

[attachment=0]Composite Materials Fabrication Manual #2.jpg[/attachment]

Creating useful composite parts requires a good design, a topic that is discussed at length in this book. The methods illustrated here lend themselves to both motorcycle and automotive builders and customizers. The construction of these parts is documented in step-by-step fashion with an abundance of photographs.

Chapter List:

Posted: **Sun Aug 14, 2011 1:57 pm**

Fiberglass Cloth

I don't want to be to basic with this topic because everybody knows what fiberglass is. But this installment is about the cloth and the different varieties available.

Fiberglass is just that! it is glass that has been spun into fiber threads then then woven into cloth form. The weaves vary as well as the size and thickness depending on what you are doing with the cloth.

This is a Chopped Fiberglass mat cloth

[attachment=3]fiberglass chopped mat.jpg[/attachment]

This is a basic weave Fiberglass

[attachment=2]fiberglass woven roving.jpg[/attachment]

There are tons of different cloth combinations and weaves from plain fiberglass with straight weaves to special composite cloth comprised of Glass, Carbon, Aramid, and so on.

[attachment=1]reflective carbon fiber fabrics.jpg[/attachment]

This kind of cloth is used to create strength while keeping the light weight advantage that cloth and resin will allow, Carbon Fiber can be as strong as steel while Aramid (Kevlar) is used to stop bullets!

Basic cloth is the most common that is used to make props and armor and that's what we will start with.

Fiberglass cloth can be purchased from your local hobby shop or you can order it on-line and is readily available.
I will list some on-line supply companies later in this thread.

The best way to get familiar with all the different types of cloth is to buy a sample pack.

This one is available through Fibre Glast corp.

This convenient Sample Pack contains a 4" x 6" swatch of our fiberglass fabrics and tapes. It is ideal for determining which material you would like to try for your application. Plus, each sample pack includes a coupon for $25 off your next order of $100 or more when purchased within 60 days!

[attachment=0]Sample Pack.jpg[/attachment]

Contains samples of:

Woven Fiberglass Fabrics

#241 2 oz/sq yd, Plain Weave, 38" Wide
#262 4 oz/sq yd, Plain Weave, 50" Wide
#259 6 oz/sq yd, Plain Weave, 38" Wide
#243, 244 7.5 oz/sq yd, Plain Weave, 38" or 50" Wide
#245, 271, 247 10 oz/sq yd, Plain Weave, 38", 50", or 60" Wide
#1543, Style 6781 S2-Glass, 9 oz/sq yd, 8H Satin Weave
#1093 Style 7715, Unidirectional, 7 oz/sq yd, Plain Weave, 38" Wide
#1094 Style 7725, Bi-Directional, 9 oz/sq yd, 2x2 Twill Weave, 38" Wide
#543 Style 7781, 9 oz/sq yd, 8HS Weave, 38" Wide
#573 Style 120, 3 oz/sq yd, 4HS Weave, 38" Wide
#254 20 oz/sq yd Tooling Fabric, Mock Leno Weave, 38" Wide
#223 18 oz/sq yd Woven Roving, Plain Weave, 50" Wide

Fiberglass Tape,

9 oz/sq yd, Plain Weave, 1" (#217,) 2" (#219,) 3" (#220,) 4" (#221,) 6" (#222,) or 12" (#224)
#246 Scrim Fabric, 50" Wide, White
#2212 Black Fiberglass, 50" Wide, Twill Weave

Non-woven Fiberglass Fabrics

Chopped Strand Mat, 1.5 oz, (#250) 38" Wide, (#1250) 50"Wide, (#492) 4" Wide
#260 Continuous Strand Surfacing Veil, 38" Wide
#251 1.5 oz/sq ft Continuous Strand Mat, 50" Wide
#522 Gun Roving, for use with chopper gun

Fiberglass Sleeve

2" Braided Fiberglass Biaxial Sleeve, 10.4oz

This sample pack is $19.95 and is available through Fibre Glast (Sample Pack)

Posted: **Sun Aug 14, 2011 2:09 pm**

Now a chrome fiber matting might give a new type of look to the Cylons. Built in chrome over plating. Now more wear and tear scratches.

Posted: **Sun Aug 14, 2011 3:37 pm**

Sample Packs Cont.

Carbon Fiber Sample Pack

This convenient Sample Pack contains 4"x6" swatches of all of our classic style carbon fabrics. It is ideal for determining which material you would like to try for your application. Plus, this Sample Pack includes a coupon for $25 off your next order of $100 or more when purchased within a 60 days! *Patterned Carbon Fiber Samples Sold Separately.

[attachment=0]Carbon Fiber Sample Pack.jpg[/attachment]

Contains samples of:

Carbon Fabrics

#1069 5.7 oz/sq yd, 3K, 2x2 Twill Weave Carbon Fiber Fabric. 50" Wide
#530 5.7 oz/sq yd, 3K Plain Weave Carbon Fiber Fabric, 50" Wide
#660 10.9 oz/sq yd, 5HS Weave Carbon Fiber Fabric, 50" Wide
#2363 3.5 oz/sq yd, 1K Plain Weave Ultralight Carbon Fiber Fabric, 42" Wide
#1064 .2 oz/sq/yd, Carbon Fiber Veil, 35.5" Wide
#2583 9 oz/sq yd, Unidirectional Carbon Fiber, 12" Wide
#2609 7.5 oz/sq yd, Braided Biaxial Sleeves, "2 Wide

Carbon Fiber Tapes,

(#597) 5.7 oz/sq yd,
(#596) 1" Wide,
(#2402) 2" Wide,
(#598) 3" Wide,
(#2415) 4"Wide,
6"Wide #2293 24K Carbon Tow

This sample pack is $14.95 and can be found here at Fibre Glast (Carbon Fiber Sample)

This company has a very good website and lots of info so I will feature and reference them throught out the thread.

Posted: **Sun Aug 14, 2011 5:28 pm**

Fiberglass weights

Fiberglass cloth comes in many weights. from .75 to 40 oz and I am sure you can get it heaver. The reason for this is many. Lamination can be many layers of different weights for the desired strength.

We use the lighter weights like .75 oz for covering planes for painting and for a finish skin or first layer on molded planes.

[attachment=0]yy1SIGGF001.jpg[/attachment]

The heavier clothes are used for strength in your laminate.

The Lighter your cloth is the easier it is to shape and bend.

I noticed most of the big suppliers do not have the .75 oz and the lightest cloth they have is around 2 oz

Sig MFG. specializes in model aircraft supplies and they carry glass cloth in 3 weights

.75 oz
1.5 oz
6 oz

They also carry Polyester Resins and we will talk about that later.

Here is there link for the cloth Sig Glass Cloth

Posted: **Sun Aug 14, 2011 5:50 pm**

Another Must Have Book

Here is one I almost forgot and we fetured this on on the Rotocasting thread. This one is a must not to mention this guy is a friend of Skullbeast. it's packed with info on mold and part making both silicone, Matrix molds, and fiberglass.

FIBERGLASS & SILICONE MATRIX MOLD By Valdez Tools[attachment=0]fiberglass-silicone-matrix-mold-by-valdez-tools-209-p.jpg[/attachment]

This one is $29.95 and you can find it here at Monster Club.Com (Book)

Posted: **Sun Aug 14, 2011 6:48 pm**

Tools

You will need a variety of tools for making fiberglass molds and laying up parts.

Laminating Tools & Supplies

Let's start with the shears and knifes

Hand Shears
Kevlar

Posted: **Sun Aug 14, 2011 7:03 pm**

Tools Cont.

Laminating Tools

White Latex Squeegee

[attachment=9]White.jpg[/attachment]

3M Wet Dry Rubber Squeegee

[attachment=8]Black_something.jpg[/attachment]

Plastic Squeegees

[attachment=7]Picture15.jpg[/attachment]

Putty Knifes

[attachment=6]All_stuco.jpg[/attachment]

Foam Brushes

[attachment=5]Foam_Brushes.jpg[/attachment]

Paint Brushes

Brushes, pure natural bristle brushes with non-painted wood handle, great for working with polyester and epoxy resins. 4" brush is industry standard for Hot Coating polyester surfboards and Sailboards.

[attachment=4]Brushes.jpg[/attachment]

Paint Rollers

[attachment=3]Rollers_and_covers.jpg[/attachment]

Aluminium Bubble Rollers

High Performance Aluminum Bubble Rollers, superior roll out time and excellent air relief properties in nearly all applications. Choose the largest diameter possible. Wood handle that accepts extension and strong steel frame. Machined with deepest fins possible for efficient air relief and excellent lay up properties.

[attachment=2]Alum_roller_H_P.jpg[/attachment]

Aluminium Radius Rollers

Aluminum Radius Rollers, designed for concave surfaces where flat roller bridge and are not effective. Wood handle that accepts extension and strong steel frame. Machined with deepest fins possible for efficient air relief and excellent lay up properties.

[attachment=1]Alum_roller_Radius.jpg[/attachment]

Aluminium Econo Rollers

[attachment=0]Alum_roller-Econo.jpg[/attachment]

Posted: **Sun Aug 14, 2011 7:42 pm**

Tools Cont. 2

Bristle Rollers

Quick Release Bristle Rollers, used when conventional finned rollers are not efficient at removing air in a particular laminate. Work well in knitted/unidirectional fabrics where air pockets can form. Quick release allows for fast clean up, strong

Posted: **Sun Aug 14, 2011 11:08 pm**

Tools Cont. 3

Fabrication Tools

Demolding Wedges

Demolding Wedges, use for removing parts from molds, prevents scratching and damaging mold surfaces.

[attachment=5]Demolding_Wedges.jpg[/attachment]

High Performance Demolding Wedges, longer lasting and tougher. Use for removing parts from molds, prevents scratching and damaging mold surfaces.

[attachment=4]IMG_4639_edited.jpg[/attachment]

Masking Tape

Tape is very important!

New Scotch 3M 233+ Masking Tape, an improved version of 233 that offers exceptional conformability, and a sharper edge for striping

[attachment=3]Picture10.jpg[/attachment]

Scotch # 2090 Long-Mask Masking Tape, Utilizes a synthetic adhesive system which provides ultraviolet stability and adhesive transfer resistance up to seven days after application. For paint and varnish masking applications.

[attachment=2]Blue_Tape.jpg[/attachment]

Tartan Masking Tape, a utility purpose tape used for holding, bundling and sealing. Not to be used for paint masking or resin work.

[attachment=1]catalog_034_edited.jpg[/attachment]

Frog Tape

[attachment=0]frogtape-product-shot.jpg[/attachment]

Posted: **Sun Aug 14, 2011 11:41 pm**

Dr. I concur! I'll just say yes to all the above.

---
- Die human!

Posted: **Mon Aug 15, 2011 12:39 am**

Skullbeast wrote:Dr. I concur! I'll just say yes to all the above.

---
- Die human!

Thank you Master Skullbeast I will continue

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Making Fiberglass Molds, Fiberglass Parts and Vacuum Bagging

Making Fiberglass Molds, Fiberglass Parts and Vacuum Bagging

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Re: Making Fiberglass Molds, Fiberglass Parts and Vacuum Bag

Re: Making Fiberglass Molds, Fiberglass Parts and Vacuum Bag

Re: Making Fiberglass Molds, Fiberglass Parts and Vacuum Bag

Re: Making Fiberglass Molds, Fiberglass Parts and Vacuum Bag

Re: Making Fiberglass Molds, Fiberglass Parts and Vacuum Bag

Re: Making Fiberglass Molds, Fiberglass Parts and Vacuum Bag

Re: Making Fiberglass Molds, Fiberglass Parts and Vacuum Bag

Re: Making Fiberglass Molds, Fiberglass Parts and Vacuum Bag

Making Fiberglass Molds, Fiberglass Parts and Vacuum Bagging

Re: Making Fiberglass Molds, Fiberglass Parts and Vacuum Bag