How to Laminate Two Fiberglass Panels Together

Surfboards and kayaks are usually made from fiberglass.

You can create almost any shape using fiberglass. Fiberglass is a combination of extruded glass and epoxy or thermosetting plastic resin that, together with a catalyst, hardens into a lightweight, durable material. Often used for boats, auto body repair and surfboards, fiberglass lends itself to use by hobbyists, artists and builders. Layer fiberglass onto wood or polystyrene foam forms. Layer fiberglass panels on top of each other to strengthen the structure. Adhere fiberglass panels to each other for a strongly bonded pair. Once cured, fiberglass can be shaped, sanded and painted.

Things You'll Need

• Chopped strand mat
• Two-part laminating epoxy resin
• Bucket
• Paint mixing sticks
• Disposable squeegee
• Laminate roller
• Rags
• Clamps

Instructions

1. Mix equal parts of the two-part epoxy in a disposable container. Mix only what you will use in a short period of time.

2. Pour a layer of mixed epoxy on the surface of the bottom fiberglass panel. Spread the layer with the squeegee.

3. Apply chopped strand mat fibers over the resin. Use the squeegee to spread the fibers. Use a new squeegee if it becomes fouled.

4. Saturate the fibers with the mixed epoxy resin. When saturated, the fibers will be clear.

5. Roll the laminate roller over the wet mix to press out any air bubbles.

6. Lightly coat the bottom of the top fiberglass panel with epoxy.

7. Place the top fiberglass panel over the wet one. Press out all air using a clean laminate roller. Work from the middle to the edge to press all the air out the sides. Clean the edges with rags as you go.

8. Tape or clamp the pieces together and allow to dry. Drying takes between two and four hours.

Tips & Warnings

• Epoxy mixing directions may vary by brand.

• Don't use paper containers to mix in, as they may contain wax.

• Wrap plastic around the edges of the fiberglass to encourage curing.

• Wear protective eyewear, gloves and long sleeves.

• Fiberglass splinters are painful and difficult to remove. Use caution when working with fiberglass.

References

• Fiberglass Site: How Much Resin Do I Need? And Everything You Need to Know About Fiberglass
• East Coast Fiberglass Supplies: Guide to Glass Reinforced Plastic (GRP)