I've not bought any fiberglass for a long time, so I thought it looked terribly expensive. The
thayercraft.com link is greatly appreciated; that's more like it. I'd never use polyester resin
for anything, even if it is a lot cheaper - it's potentially dangerous and has the most rotten,
horrible smell. JMO.
Epoxy is a hazardous material as well, but stronger and easier to work with IMO. Fiberglass is
adequately strong for items like wheel pants, and much cheaper and better conforming. I like to
use a finer weave fiberglass material for the outer surface layer.
What ultimately worked best for me was rubber molds, made with a wooden plug, and later I
poured the female mold full of rubber to make a plug to fit it. This allowed me to fully saturate
the fiberglass cloth (overly so) in the female mold, then use the rubber male plug to compress it
and squeeze out excess and avoid bubbles.
It's not all that difficult to do, and the good epoxy resin goes a long way toward success. More
sophisticated and durable molds can be built if you plan to mold a larger number of parts.
That said, I don't feel I'd be capable of molding a decent quality fuselage or wing - but my crude
methods did produce reasonable small items.
L.
"All major weaknesses have been exposed, analyzed, and replaced with new
weaknesses." -Bruce Leverett