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Plugs are secured and we can carry on with the moulds.
From time to time someone is asking how to actually laminate so I will allow myself to show how I am doing it. You have to start with getting such set of tools and materials.
We have here epoxy resin, hardener, scale, plastic containers, thicknesser for the resin, paint/dye/pigment, paper towels, two types of fibre cloth 120 and 250 g/m2, scissors, brush and rubber gloves.
We build the mould in 2 stages - first is to cover the plug with so called gel coat.
Plug covered with gelcoat If we skip that layer then on the surface of the mould we would see the pattern of fibre glass cloth and we do not want that. Ready made gelcoats can be obtained but for modelling at home self made gelocat is just as good. We mix appropriate amount of resin and hardener (see your resin’s manufacturers details for ratios) and to have some contrast we add dye. Now we have to thicken the mixture – we can add talc or something called aerosil. Thickened resin does not drift on vertical surfaces. The mixture should look and feel like thick cream. With that we paint the plug. We put the mixture in all corners and we put so much trying to make those corners round on the outside. Later on the cloth will better stick to them.
This is how the plug looks like after covering it with gelcoat. I used 40 grams of resin. Now we leave it until resin start to settle or crosslink i.e. when you can already touch it with finger but it is still soft. It takes about 3-4 hours in temperature of around 20°C. If warmer then the process is faster.
Now we can apply the cloth. I mix the resin, now without any thicknessers, and with brush I apply thin layer on the gelcoat and finally I put first layer of cloth on it. As first layer I use thinner cloth e.g. 120 g/m2. It is easier to spread into all corners. Do not try to cover everything with one piece of cloth. We soak the cloth in resin with brush until it becomes glassy. With brush we also push out any air bubbles. Further layers can be covered with thicker cloths already. For my deckhouse I used 3 layers of 250 g/m2. For this operation another 40 g of resin were used. There is no point saving here, the walls of the mould must be hard.
So this is how it looks like after lamination. Extras are cut off, wooden planks enforce the mould. We leave it 24 hours or even 48 hours. When everything has hardened we take out the plug.
Ready mould and its plug, not cleaned yet with visible separator. Remains of dry polyvinyl alcohol can be washed away with warm water. Ready mould should be waxed minimum with 6 layers, and each very well polished. In the end can also be painted with alcohol.
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