Table of Contents
- 2The size of the thing
- 3About the measurements used
- 4A visual index
- 5Overview of the head
- 6Step 1.1. The head side-frames.
- 7Step 1.2. The head inner support structure.
- 8Step 1.3. The form (mold) for the hypertufa.
- 9Step 1.4. Hypertufa
- 10Placing the hypertufa
- 11Hypertufa - The curing process
- 12Step 1.5. Slurry
- 13Off with the formwork
- 14Step 1.6. The head side-covers and the crown
- 15The crown
- 16Fixing the trim to the side-covers
- 17Step 1.7. Fiberglass
- 18Step 1.8. Paint - undercoating the head
- 19Overview of the body frame
- 20Step 2.1. Shaping the frame members
- 21Step 2.2. Cutting the frame members to length
- 22Step 2.3. Making the wall frames
- 23Step 2.4. The body frame
- 24Step 2.5. The shackles
- 25Overview of the Neck
- 26Step 3.1. The neck - making the box unit
- 27Step 3.2. The aluminum angle for the sign
- 28Step 3.3. Internal perimeter pieces
- 29Step 3.4. Fitting the neck
- 30Step 3.5. The telephone sign
- 31Step 4.1. The trim around the door and window openings
- 32Door and window overview and plan
- 33Step 4.2. Wood for the door and windows
- 34Step 4.3. Joining the stiles and rails
- 35Step 4.4. Notching the muntin bars
- 36Step 4.5. Fixing the muntin bars
- 37Step 4.6. Painting the door and windows
- 38Step 4.7. The acrylic sheet
- 39Step 5.1. Making the base
- 40Step 5.2. Some painting
- 41Step 6.1. Putting it all together
- 42Some strengthening and the door closer
- 43The desired effect
- 44Step 7.1. The rose and ceiling
- 45Making the rose pattern
- 46Marking, drilling, and cutting the rose
- 47Tapering the rose
- 48Painting and fitting the ceiling and rose
- 49The light goes on
- 50The plans
Step 1.7. Fiberglass
For our first venture into fiberglassing we found it a very easy craft to master, or at least within the realms of our requirements.
We used an epoxy resin and some fiberglass cloth. It basically entailed brushing on a coat of epoxy resin, laying a fiberglass cloth over that, and then brushing another coat of epoxy resin over that.
Important! When doing this, ensure that appropriate clothing is worn along with good gloves and a suitable breathing mask.
This is our account of proceedings
The resin and hardener were mixed to the ratios stated on the bottles – different brands have different ratios. The amount used for the first coat was approximately 200ml (1/3 of a pint) including the hardener.
That lot was then poured on top of the dome and brushed all over. A bit like painting.
Note: Mixing the epoxy resin in a wider type container and having a quick pour, avoids a mass of catalysed resin exotherming (in plain English, getting very hot). Although with the little amount we used that wasn’t really going to be a great problem.
Once the epoxy resin was spread over the working surface, we lay a covering sheet of 100gm (3½ ounce) weave fiberglass cloth over the top of it.
Note: You can either lay the fiberglass cloth over the epoxy resin directly after application, or you can wait till the epoxy resin has dried to the touch – maybe three or four hours later. The latter makes it a little easier to spread the cloth, the former gets the job over and done with.