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How to Build Wood Core Fiberglass

Placing fiberglass over a wood core provides a stable, thick surface that is suitable for a variety of uses. Typically, wood cores are used with boats, auto modifications and additions and speaker boxes. Using a wood core will produce a heavier object than a core made from a lighter material, such as cardboard, but it will produce long-lasting results. The fiberglass will prevent the wood from flexing, which can cause problems for wood that has lost its integrity. Whenever possible, use new wood as a fiberglass core.

Things You'll Need

Wood surface
Fiberglass resin
Fiberglass hardener
Foam roller
Fiberglass mat
Scissors
Thick work gloves
Paintbrush
80-, 120- and 400-grit sandpaper

Instructions

- 1
  Mix five parts resin with one part hardener. Roll the resin onto the wood surface with the foam roller. Allow the resin to sit for 15 minutes; then apply a second thin coat of resin over the wood.
- 2
  Wear work gloves, and cut the fiberglass sheets into 12-by-12-inch squares for large surfaces. Use smaller, 3-by-3-inch squares for smaller surfaces. Lay the fiberglass sheets over the wet resin. Apply an additional coat of resin over the sheets until the fiberglass is saturated with resin. Allow the resin to dry for two or three hours.
- 3
  Apply a fill coat over the fiberglass with the foam roller. Apply enough resin to fill in the ridges of the fiberglass. Allow the coat to dry for two or three hours.
- 4
  Apply up to three layers of fiberglass sheeting, applying a base coat, bond coat and fill coat to each layer.
- 5
  Apply a final top coat over the final layer of fiberglass with the foam roller. Use a paintbrush to smooth out any rough areas. Allow the resin to harden for 24 hours.
- 6
  Sand the surface of the fiberglass gently with sandpaper to remove any rough areas and smooth the fiberglass. Start with the roughest grades of paper, and work up to the finest grits. Wipe away any dust with a damp cloth.

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