coating a foam plug


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si3211
si3211
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http://www.talkcomposites.com/Uploads/Images/21e5373c-40e6-4703-ac92-9855.JPGI've roughed out a foam plug for some new bodywork working off cad drawings. I've used celotex type low density insulation and i'm now looking to start coating and filling. I was considering covering the foam plug in a fibreglass skin and then building up the finish in layers of polyester primer filler. Can you recommend a suitable cloth and a whether I can use a polyester resin or ?. I have made the plug approx. 3mm smaller than the finished item to allow for a finished build up. ( I attach a photo pre sanding to give an idea of curvatures. Thanks
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Hanaldo
Hanaldo
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Always better to do a test using the stuff you've got, there's so many different types of foam it's easy for us to say it will work and then you go and put polyester resin on and it all melts away. Or what I have found with some foams is that the appear to withstand the resin, but 2 days later you are sanding it and the resin just gives way and you find the foam has gone extremely brittle and crumbly. 

If it doesn't work with polyester that's not really a big deal, you can just seal the foam with epoxy and allow it to cure, then you can glass as per normal over the top of that. I wouldn't be going any heavier than a 225g csm over the foam, a 100g csm would be better. Then body filler over that to shape/smooth. 
GO

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