Lol That nice smooth outer surface is the 1st step Ken,If you are gel coating it gets sprayed on mold 1st,then the layers of resin and cloth,the stuff that looks like smashed cotton candy as U say Im thinking its "core mat",it is used to get a thickness,instead of a bunch of layers of mat me thinks,have never used it,would like to find some local but haven't been able to locate,an don't wana take chance on mail ordering it.I'm not gel coating so after the PVA is sprayed on I roll resin on it,then 10oz fine woven cloth (gets all bends an curves,body lines etc)then I used 2 layers of 20-24oz woven cloth,after that drys I put on 2 more layers of the 24oz stuff,and lay inner wood frame in wet door,then I put some cut to fit pcs of 2x4 were latches and struts mount,then glass over the frame & pcs.
Got some pics coming tomorrow afternoon,rainin cats & Dogs rite now,and back is kickin....time for heat pad! >>>>>>

Cool! Thanks. Do you let each layer dry first or is it all done while wet? If done wet, I guess you need to work fast so resin doesn't harden before you are done.

The 3 layers I just did on door was done in 1 mix of resin,lost about 1-1/2pts it started settin up,once it starts it dont stop!! I mix 1-gal resin w/1+1/3oz hardner and get like 20-25 mins work time! the hotter it is out the less hardner,and colder needs more!When it starts to set up it looks like jello

Looking great.Thank you for posting pictures and sharing this great info......

K worked on door somemore,brought camera in to unload some pics so....
k got the 3 layers of cloth on mold...

Let that setup,then put another layer on....

Then wet that out....
The PVA stuff works perty good,you can C how it makes a film like on mold...

Cut edges some....


Did some sandin on edges....

laid frame in to check fit....
Lookin fairly good
Now to clean up some mess......

Will post somemore pics when I glass the wood inner frame an stuff in>>>>>>>
I think im going to pop it loose from mold before I glass inner wood frame in me thinks,mite come loose little easyer from mold I think!

Thanx Lukester!

Today we pulled door skin from mold....

Took thin puddy knife an went in @ corner an worked up skin,PVA stuff works perty good! leave like a green ish film,that pulls and rolls up good!




Door skin looks perty good

Wanted to separate it before I glassed the inner frame in,figured it would come loose easier beings its more flexible,so we cleaned up all PVA & mold & skin,an laid it back together an did some clampin! want skin to keep shape as glass to frame using mold....

then we cut some strips of cloth to glass back of skin to the inner wood frame....




The Im glassin some 2X4 blocks in were strut & latchs will mount...

Well going to take Beer break....
What do any of U guys use to cut fiberglass mat and woven cloth with? I been using these but they R getting dull.....stuff is tough on sissors!!


O an stinkbugs are coming back!! Seen this catcher on internet an made one,It the top of water bottle cut off on inverted and taped! I taped it to long stick and ya put it over and brush the bug and he falls in and cant get out!! LMAO its even more fun after a couple beers!!


K more next time>>>>>>>>>>>>>>>>>

great work & nice lil bug catcher.

Beautifull Work!!,as for cutting the woven fiberglass mat,i use sewing sissors,the ones that have the zig zag blades and they leave a good cut without distorting the mat.

Thanx, a guy gota patten on the Bug Catcher! Got a 2 liter bottle with little battery light in bottom,for catching them at nite,they drawn to lite and heat!!