Fiberglass Fin Stock

There have been times that I've wanted to use a fin material that is thinner and more rugged than plywood, but I'm usually too cheap to purchase G10. Not only is it pretty expensive, but I don't know where I'd buy it locally - which means shipping charges and (even worse) waiting for it to arrive. So instead of buying G10, I decided that I would make a flat sheet of cheap fin stock with the extra resin and scraps of fiberglass mat I have lying around. This would still be cheap even if I was only buying small quantities of the materials I needed -- auto parts stores sell it in small quantities as body repair materials.

If you've ever wanted to try fiberglassing and wanted a simple project to get started, this is as simple as it gets. If you want an overview of composites and how to use them, check out the articles available [HERE!] and [HERE!].

Materials

Instructions

1. Cut three pieces of fiberglass mat 12 inches long and 6 inches wide.
2. Cut the whiteboard into two pieces about 8 inches by 14 inches.
3. Apply several coats of carnauba wax to the melamine (white) side to act as a release agent.
4. Center a piece of mat on the whiteboard (white side up) and soak with mixed resin/catalyst using a disposable brush. Add the second and third layers, soaking each thoroughly and working out the bubbles.
5. Place the second piece of whiteboard over the top (white side down). For good measure, place a board over the top of the stack and lay some weight on that. Leave it alone until it cures, then peel it apart.
6. Trace your fin pattern onto the stock and trim with a band saw or coping saw. Sand the edges.
7. Fill surface imperfections with spot putty and sand smooth.

I've also used this material for mounting electronics and digital cameras in the avionics bay, for centering rings, mirrors (to deflect camera angles) and more.