How to: Fiberglass Wings

Create durable fairy wings out of fiberglass.

Fairy wings are a part of many fantasy costumes, but store-bought ones are often flimsy and are only available in a variety of shapes. If you want wings that are a customized size and shape, you can make your own out of fiberglass. You will build these wings on a cardboard form, making them very strong yet lightweight. Once you have finished the wings, you can decorate them in whatever way suits your imagination.

Things You'll Need

• Cardboard
• Razor blade
• Hot glue gun
• Plastic tarp
• Fiberglass resin and catalyst
• Mixing buckets
• Mixing sticks
• Cheap paint brushes
• Fiberglass mat
• Rotary tool
• Sandpaper
• Spray primer
• Paint and other decorating materials
• Old backpack
• Scissors
• Needle and thread
• Goggles, dust mask and gloves

Instructions

1. Cut out two matching wings from sheets of cardboard with a razor blade. These wings should have a 12-inch flat edge where they will attach to your back.

2. Cut a rectangle out of cardboard that measures 12 inches by 6 inches. This will be the flat piece that fits against your back.

3. Connect the 12-inch edges of the wings to the 12-inch sides of the rectangle with hot glue. The wings should angle outward so they can be seen while you wear them.

4. Place a plastic tarp on the ground, and place the cardboard wing form onto the tarp. It should rest on the rectangle with the wings up in the air.

5. Mix a batch of fiberglass resin with its catalyst in a disposable bucket. Consult the resin container for the proper mixing ratio: too much catalyst will cause the resin to cure too quickly, while not enough catalyst may prevent the resin from curing at all.

6. Brush a layer of catalyzed resin onto the cardboard with a cheap paint brush. Allow the resin to harden, which will stiffen the cardboard.

7. Tear fiberglass mat into squares measuring between four and six inches depending on the size of the wings.

8. Mix another batch of fiberglass resin with catalyst in a fresh bucket.

9. Brush a layer of catalyzed resin onto the cardboard, then lay overlapping squares of fiberglass mat into the resin. You will cover the entire cardboard surface.

10. Tap more resin into the fiberglass, saturating it fully and working out any air bubbles.

11. Apply a second layer of fiberglass and resin onto the wings.

12. Allow the fiberglass to harden for several hours.

13. Remove the wings from the tarp and trim off the rough edges with a rotary tool.

14. Set the wings back on the tarp, rectangle-side up, and apply fiberglass to the bottom of the rectangle.

15. Allow the wings to dry overnight.

16. Cut a horizontal 1-inch slit in all four corners of the rectangle. You will attach straps to these when the wings are finished.

17. Sand the entire fiberglass surface with 120-grit sandpaper to remove any rough portions.

18. Wipe the wings with acetone on a rag to remove any sanding dust.

19. Spray three thin coats of primer onto the wings, allowing each coat to dry completely.

20. Paint the wings as desired. You can also decorate them with glitter, feathers or any other craft material.

21. Cut the adjustable straps off of an old backpack with a pair of scissors. Loop them through the slits in the rectangle and sew them in place.

Tips & Warnings

• Wear rubber gloves when working with fiberglass.

• Wear goggles and a dust mask when cutting and sanding fiberglass.

References

• Microship: "Building Composite Structures with Cardboard"; Steven K. Roberts; 2004
• AJ QUICK: Fiberglass Tutorial