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Now the cutting process begins.

Foam template cut and stacked together.

Originally I had planned on shaping the final edges of each template (using files and sandpaper) to form the mould but I soon realised that I hadn't given enough thought to the final dimensions. I decided to err o the side of caution and filled the steps with modelling clay (Plastercine). I'm starting to feel very pleased with myself at this stage. The issues I had obtaining materials and then the day spent manufacturing these sheets demoralised me quite a bit.

Now to the fibre glassing…

I did some Google researching before this, and but went head on into it, trial and error style, anyway. Naturally, the 'error' of trial and error emerged. The proportions of catalyst must be precise! I had trouble ensuring 0.5ml of catalyst to 50g of resin. I realised the gravity of this when my first resin soaked fibreglass didn't harden. I ripped it all off the mould and started the FRG process again. This time, impatience weighing heavy, I didn't bother brushing the resin on first, instead I placed the fibreglass strips over the mould as best I could and then brushed the resin into it. All these things get very sticky and hard to work with. If I had help or another pair of hands, things would have been better.

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