How would I go about making something from Glass reinforced Fibre?

Question

http://en.wikipedia.org/wiki/Fiberglass_molding

Ok wikipedia helps a bit, first step first I need to make a mould, but how would I go about doing this? Esspecially if i wanted something quite large with smooth flowing curves?

Answer 1

You can make a mould from polystyrene or styrofoam.  You will probably have to support it with a wooden frame.  Also, after you have shaped it to your requirement, you need to paint it with a couple of coats of emulsion paint since fibre glass resin dissolves the foam instantly.

The best way is to make a positive mould from polystyrene or something, then make a negative mould by covering the positive mould with fibre-glass.  Once this is set, remove it and polish the inside.  Then you can form your finished moulding inside it.  Its a lot of work to get it right.

Answer 2

you can mould from any shape as long as you can separate the mould from the moulding after it has set hard.

you have to apply a release agent (wax) so that the new moulding is not bonded to the mould

if the shape you want is complex you will have to make sections and join them afterwards

Answer 3

Most people build their forms out of styrofoam since it can be carved and sanded.