Creating a simple box shape with GRP fibreglass in a melamine mould

[@Reman1975]

Interesting. At some point soon I need to build an odd sized (7x16') semi permanent shed that can be assembled by one person. I initially thought of welding up 6x4 and 7x4 steel box section frames for the side walls, a pair of 3'6" wide panels with the sloped roof angle on the top for the back wall, and a couple of door frame halves for the front, then skinning all these in painted 9mm plywood. But these panels would end up being ridiculously heavy......... And have you seen the price of plywood at the minute !!! I've never had much luck with fibreglass moulding in the past, but after seeing this video I'm thinking I might need to look into the possibility (And costs involved) of making the walls in a similar way to how you made these doors. Maybe if I encapsulated a "Batten wood" frame around the edges, and a couple vertical wooden stringers up the middle, it might even be strong enough without most of the metal framework? I just need to work out what kind of loads the walls could see if the corrugated sheet roof I'm intending to use had, for example, a foot of snow all across it, and how much it would cost in materials per panel to make them structural enough to carry that. 🤔

[@alwackiefunhouse]

Hi, Great video, thank you for posting. I'd like to make a fiberglass box for my boat. What is the name of the board you use to add thickness to your construction? Thanks a bunch.

[@ecfibreglassuk]

Hi, We are using Nidaplast as our core material www.ecfibreglasssupplies.co.uk/nidaplast

[@stonertravis]

had exact same question and want to do the same exact thing. How'd it turn out?!

[@radiogramgramophonetoons5802]

What did you do with the rest of the catalysed white gelcoat, that you didn’t use in the mould ?

[@ecfibreglassuk]

This was also used on a neighbouring mould for another project. However in an instance where you have mixed up too much gelcoat it is best to scrape the excess gelcoat into a metal tin and leave outside. if you work from make sure its not accessible to children, pets etc . just like resin excess gelcoat left in a pot can get hot and start to smoke so you do not want to be breathing in those toxic fumes. once it starts to gel off you can pour cold water in the tin also to cool down the reaction.

[@amjadhani8929]

Good video

[@macaalf8219]

Shouldn't the resin be tacky rather than fully cured between layers?

[@ecfibreglassuk]

Ideally the next layer should be applied within 24 hours after it has tacked off. however any period between 24-48 hours the next layer can be applied and will still have a very good chemical adhesion, providing the working environment isn't dusty or at risk from contamination from other workshop processes. Depending on the resin being used you should always follow the product tech data sheet with regards to application as advice can vary. however when it comes to Gelcoat you should always apply whilst the gelcoat has a surface tack but not if the colour comes off on your fingers as this will indicate that it hasn't cured quite enough. applying resin too early to gelcoat can result in pickling/wrinkling of the gelcoat

[@grahamjt3]

Hi guys, just wondering do you change the resin for the final coat. I take it you use a laminating resin and gelcoat to start off with. Do you add wax to the final coat to allow it to fully cure? Thanks

[@traveling-taylors]

Also what was the reinforcement on the edges please

[@ecfibreglassuk]

we first used a Gelcoat and let that cure, then we continued throughout with a Lloyds approved polyester resin we didn't add any wax to the final coat however this is an option if you wanted further protection or a smoother easy to clean surface for say a marine application?

[@ecfibreglassuk]

@@traveling-taylors the reinforcement was a uniderectional fibreglass tape or you can use biaxial tape just to give more reinforcement to the out edges and to where fittings may be fixed.

[@radiogramgramophonetoons5802]

Was that 1 layer of 1oz and followed by 2 layers of 1 1/2 oz mat ?

[@ecfibreglassuk]

HI, it was, the 1oz tends to get into those corners a lot easier for the first layer.

[@AtuleAbraham]

How can I get some of your tools in Ghana west Africa

[@ecfibreglassuk]

HI Unfortunately we do not have any suppliers in Ghana.

[@AtuleAbraham]

@@ecfibreglassuk so what can I do to be able to get some of your item

[@philfromsalisbury4538]

Hi What is the aprox material cost for this project , not counting the mold Many thanks

[@ecfibreglassuk]

I'm not sure you would need to speak to our sales and tech team direct with your sizes and specification etc.

[@radiogramgramophonetoons5802]

Takes longer to let 1st layer cure, when each layer is just as easy as the first

[@pierremitham2964]

Unusal technique, looks like you used gelcoat or pigmented resin for the bulk of the layup.

[@ecfibreglassuk]

yes, it is a low budget method of moulding, we would often advise on making a proper professional polished mould if going into panel production. However some projects don't warrant the expense of moulding making for say a one off or temporary panel this method is quite popular for bespoke camper shower tray, water tanks, boat fishing boxes, pontoon boxes and lids etc . We did use a pigmented gel coat first then layed up with a white pigmented resin.

[@BBBA_]

WHITE RESIN LOOKS MUCH BETTER THAN YELLOW RESIN.

[@artongashi6206]

How harmful is it to human health Wax, PVA, Gelcoat and polyester resin, and is there any problem in working without protective mask ever.

[@ecfibreglassuk]

They all have an element of risk we would always recommend consulting the safety data sheet for any chemicals such as resins, release agents, solvents etc that you buy online and follow the advice given where it refers to personal protection. We are fortunate to have a good extraction system and have VOC levels monitored regular throughout our facility, however we always wear vapour masks if working on any larger projects where styrene and other vapour levels may be high. Usually small projects like this in the open air or well ventilated room is ok but always keep your skin covered and your eyes protected with goggles when using this material. Styrene is heavier than air so even outdoors we would advise wearing a vapour mask if your likely to have your face in close contact with these vapours. so on projects where your down in an open boat hull mould for example where there isn't much airflow then make sure you wear a mask. if its an enclosed space such as for large tank lining then a mask connected to a constant air supply tank would be recommended. again always consult the safety data sheet and speak to your PPE equipment supplier for more comprehensive advice on types of masks ,filters etc.

[@artongashi6206]

@@ecfibreglassuk Should the eyes be protected from the gas vapor or should the eyes be protected from any drop of these products?

[@ecfibreglassuk]

@@artongashi6206 eye protection is always advised and this is mainly to protect from chemical splashes during the wet lay-up process and mixing. also to protect from debris when trimming.

[@jimspc07]

Fibreglassing good but having a solid unvented door with a gas meter behind cant be legal. Also any gas leak will fill the wall cavity. Yes, they are not made to leak. And ships are not made to sink are they? Glad I don't live anywhere this.

[@ecfibreglassuk]

This video is mainly to show how you can mould with fibreglass using melomine and not so much about gas meter cupboard door manufacture. The process can be adapted for any simple fibreglass molding projects such as boat boxes, locker, seats etc and it is the responsibility of the customer to research any further requirements regarding fittings etc that they need to add later, we only cover the fibreglass part of the advice to demonstrate teh materials we sell. although vents were added later to these doors as well as lock fittings etc also not shown in the video.

[@artongashi6206]

How harmful is it to human health Wax, PVA, Gelcoat and polyester resin, and is there any problem in working without protective mask ever.

[@blcouch]

If you have decent airflow (as from a box fan, across your work area) and aren’t in an enclosed area, small jobs like this are fine without protective masks. Larger jobs or enclosed areas change things a bit.