In this phase of constructing our life-sized Warg statue, we're focusing on reinforcing the structure using fiberglass cloth and West Systems Epoxy. This is essential as the reinforced model will later serve as the base for a silicone mold and shell. Here's a detailed look at how to strengthen the seams inside the model to ensure it withstands the rigors of movement.
Preparing the Workspace
Before beginning, I set things up in a well-ventilated workspace, crucial when working with materials like resins that can emit fumes. All work surfaces are covered with plastic sheeting to catch drips or spills, and I always make sure to have good lighting to see the work clearly, which is particularly important when ensuring the fiberglass is properly saturated.
Material Handling and Safety
Safety is paramount when handling chemicals and materials like epoxy and fiberglass. Along with wearing rubber gloves, I use a respirator and safety glasses to protect against fumes and fiberglass particles. Epoxy is can be a skin sensitizer. As someone who has developed allergies over the years to things such as Neoprene and Red Oak, it is something I take seriously. I make certain to protect my skin wearing long sleeves and the appropriate protective clothing.
Mixing the Epoxy
Using a digital kitchen scale, I measure the epoxy and hardener at a more or less precise 1:5 ratio by weight. I have found that this type of epoxy resin is pretty forgiving as far as mixing ratios go. Thorough mixing is crucial to achieve an even consistency and optimal cure. I mix about 100-150 grams at a time for this o which I find is the right amount to use before the mixture begins to gel, typically within 15 minutes.
Applying the Fiberglass
I start by applying a thin coat of mixed epoxy onto the areas where I’ll apply the fiberglass, using a disposable brush. I then lay down strips of fiberglass cloth over the joints. It’s important to press and smooth the cloth into the epoxy, working it around any irregular surfaces. If there are irregular surface I find it is easier to press the cloth into the resin where it will easily conform and not being so concerned with the irregular areas until this section has wetted out. It takes a little time for the epoxy to work its way around the fibers and weave of cloth. When I see the fiberglass turn from bright white to nearly transparent, I know that I can use that section as somewhat of an anchor as I work the fiberglass cloth into the tighter areas. It's crucial not to over-saturate; just enough epoxy to wet out the cloth is perfect.
Using Slow Hardener
The slow hardener gives me sufficient time to work with the epoxy, especially useful when covering large areas. After setting the fiberglass, I mix leftover resin with phenolic micro-balloons to create a thick paste, perfect for filling any gaps or imperfections. Depending on the need, I adjust the thickness of this paste to be on the wet side, used to bond layers together, or a little drier to fill and fair with minimal sagging.
I have also learned the hard way (by applying fiberglass cloth to the deck of a small wooden sailboat in the middle of summer, in direct sunlight) that heat will dramatically affect the working time of epoxy resin and once the epoxy kicks, there is nothing you can do to stop it. For this task, I have been keeping the room I am working in in the 50's. This adds a little more working time into the epoxy
Cleanup Tips
Working with epoxy and fiberglass can be messy. I wear rubber gloves and lay down parchment paper where I'm working to catch spills. For cleaning uncured epoxy from tools or unwanted places, white vinegar is effective. Though it can clean disposable brushes, I find it's usually not worth the effort compared to using a new brush for each application.
Conclusion
By reinforcing the statue with fiberglass and epoxy, we ensure it has the strength to stand up to future use and handling. This methodical approach not only secures the model’s durability which is critical for the later stages of the project, such as creating the mold for eventual casting on concrete.The steps we’ve taken are crucial in building a solid foundation that is robust and well-aligned, ready for the next phases of this creative journey.
