Fabrication Skills

It's been hectic at work lately so I haven't had the time to do much prototyping. I did however start working on my fabrication skills and technique this weekend. Unless otherwise dictated by specification I will be making all "body parts" out of fiberglass. The way I intend to arrive at a finished fiberglass part is still a work in progress, but here's how I'm approaching it...

• Create object out of high density foam, the kind florists tend to use. It's easier to cut. 
• Cover in general purpose Bondo. I had my first run at this, not too hard once you get the hang of it. A couple of downsides to this... The Smell & the Quick Set Time (3-5min)
• Sand Bondo with 80 grit then 220 grid sand paper to smooth out surface. 
• Paint Bondo with Polyurethane Paint
• Apply Mold Release wax
• Apply Fiberglass Resin & Fiberglass Cloth

Here is the tool list:

• Power Sander, B&D Mouse (hand sanding was taking too long!)
• Flexible Plastic Cutting Board (worked out better than putty knife)
• Respirator (No Bondo Smell!)

Here is the consumables list:

• Bondo
• Fiberglass Resin
• Fiberglass Cloth 
• .7 Mil Plastic Drop Cloth 
• Spray Adhesive (for gluing foam parts)
• Foam Blocks
• Nitrile Gloves
• Scotch Brite Pads (for cleaning Bondo/Resin off whatever)
• Acetone (Does not play well with plastic, watch out)

Once I have it down I will photo document the process and post it. 

-Eric