Making a Fiberglass "Copy"

[1koerner]

cant u just glass over the wood then sand it down to fit where u want it ?

Not really. The wood piece is a very tight fit. Glassing around it would make it not fit. Then sanding it down to make it fit would take it back down to the wood.

got ya I was just trying to think of a easy way for u to do it

[OrionStang]

Not worried about weight. The problem I have is, the piece needs to be able to bend and not break, to get it into position between the box and the car. Here is the 1/2" mdf trim piece after trying to get it in.

[ALPINE408]

You could also cut the same piece smaller then fiberglass it should fit if your good

[ALPINE408]

Ummm fiberglass that thick and you want it to bend? Not break?

[SnowDrifter]

Vacuum bag some glass/resin into sheets the approximate shape and thickness you want, attach it to the wood, then hit it with a flush trim bit?

[mttornquist]

Vacuum bag some glass/resin into sheets the approximate shape and thickness you want, attach it to the wood, then hit it with a flush trim bit?

I was going to suggest a nylon type sheet then trim bit it to shape

[OrionStang]

Ummm fiberglass that thick and you want it to bend? Not break?

I told you Im a novice LOL.

Vacuum bag some glass/resin into sheets the approximate shape and thickness you want, attach it to the wood, then hit it with a flush trim bit?

Looking for a simple solution. Sounds good, but damn a lot of work LOL.

I may have to drop $$$ on a half sheet of birch. I don't think it will snap like the mdf did.

[CleanSierra]

Ken, can you do two smaller pieces, like 1/2 inch or so and sandwich fiberglass layers and resin BETWEEN the pieces and have that be the adhesive that holds them together?

So you'd have a 1/2" sheet, fiberglass and resin, 1/2" sheet and then cut it into the shape you have there? It should be tough and bendy enough to get into its spot without breaking.

[CleanSierra]

Pictures coming

[Blue]

This is how I would do it if you are wanting the glass piece. Get another sheet of 1/2" mdf (24x48 sheet). Lay 2 layers of blue painters tape on the wood in a crisscross pattern. Next take the broken pieces and try to get them to match up the best you can and lay them on the sheet . take a sharpie and trace the edges. Now remove the pieces and put car wax on the painters tape, covering a couple inches on each side of the lines. Do 2 layers of wax. While the wax is drying start cutting your glass to fit the lines, with them overlapping an inch or so on each side. Going to need to cut a lot since you are wanting 1/4" to 1/2" thick. Going to guess about 8 layers worth. Now put resin on the piece and then lay the glass. Keep on doing that process till you reach your desired thickness. Let it cure a day or 2 then pull from the wood and trip to the inside of the lines as best you can. Walla, got you your fiberglass piece.