Fiberglass Boxed for Seats DIY ?
 

One of the guys had a pro make a pair of really nice fiberglass box seats to mount pedestals onto. I have a few questions as I've never manufactured from scratch - just lots of repair and resto. stuff.

It looks like a design was built out of a composite material and then glassed over ( as opposed to making a mold )

What material can be used to build with ? How do you make nice curved radius' on the corners ?

How and with what would you insulate for a fish box ?

Or, is it easier to make a mold, mold release, clay radius' and go that route ?

A lot of questions to answer in one post! I'll give you my input, not necessarily right but my opinion and I am sure someone will then chime in.

First go through Stricks post here we go again for making molds and etc. You can also go through my build and see some of what I did to answer insulation and radius questions.

My answer to build and glass vs. mold and release is this. When you build 1st. and glass over, there is fairing to be done to cover the mat...fairing means a lot of sanding.

Mold building is great if you understand how to build a female mold so you're part comes out right...if done correctly no sanding and the part is almost ready to go.

Problem is it can be a step learning curve. Again check out the builds above and i think you will come to answer your own questions....WHAT IS MY PAIN LEVEL...:D

I'll check out yours and Stricks stuff. I know both of your work from the site - it''s outta-sight.

I do like making the mold idea best - I have learned to hate sanding fiberglass after so many projects :)

Having tried both methods I felt that building a mold is faster as there is less fairing involved. I like working with core cell but I see lots of other composites used. You can use core cell for either technique. As for making smooth corners and edges I would think a router and a good rasp are your best friends. Seen guys glass in blue board foam for insulation around the fish box. Expanding foam works well also. Dave (Blue Heron) has made the best box seats I've seen on the site. Check out his thred on the 25 he restored.

strick

I agree with that! He is an incredible craftsman and has taught/helped me a lot with his fiberglass knowledge.

A mold is the way to go. Way less fairing and you don't have a part full of fairing compound that will crack. Did I mention less fairing... Less sanding the better.
I use this tool you can get from a fiberglass supplier, it has two sides for large radius and smaller radiuses. The pink stuff is clay.

http://i1291.photobucket.com/albums/...ps0c2d1e63.jpg

Frizzle,

What type of clay do YOU use?