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How to Form Fiberglass End Grain Balsa Panels

Fiberglass panels are made with fiberglass matting that uses a core material for structural support. If you want to make your fiberglass panels as light as possible, you can use balsa wood for the core. To do this you need to first determine the size that is needed for a panel. You can then begin applying the fiberglass to form the panels.

Things You'll Need

Balsa wood sheet
Hobby knife or utility knife
Sandpaper
Clean cloth
Fiberglass matting
Scissors
Fiberglass resin
Brush

Instructions

- 1
  Measure a sheet of balsa wood to the dimensions you need with a tape measure. Make cut marks using the pencil. Cut the balsa wood to the required size with the hobby knife or a utility knife.
- 2
  Sand the surface of the balsa wood smooth using the sandpaper. Wipe off the sanding dust with a clean cloth.
- 3
  Measure the fiberglass matting to 1/2 the width of the Balsa wood. Cut a piece of matting to this size using scissors. Repeat this step to cut an additional 7 pieces of fiberglass matting.
- 4
  Lay two strips of fiberglass matting on one side of the balsa wood. Overlap one edge of the matting by 2 inches.
- 5
  Add the hardener to the fiberglass resin and mix according to the instructions. Pour the fiberglass resin onto the matting and smooth with the brush. Allow the first coat to set for 30 minutes. Repeat this step to add one to two more coats of resin.
- 6
  Turn the balsa wood panel over to expose the wood side of the panel. Lay two more strips of fiberglass matting over the wood and overlap one edge. Mix the resin and brush it on the matting. Repeat this step to apply one to two more coats. Allow the fiberglass resin to dry.
- 7
  Sand the surface of the panel smooth with the sandpaper.

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