These are the times when those words of encouragement are much appreciated.
Pepping the body armor...is a NIGHTMARE.
-Materials: Pepped parts, Welding Blanket (uncoated fiberglass), fiber glass resin.
-Tools: Gloves and paint brushes.
Maybe it was a case of a self fulfilling prophecy, but this did not go well.
I read on this board that its better to apply the initial resin coat to the inside of the armor (so that gravity helps keep a round shape on the body armor instead of risking it collapsing in on itself). While I have no doubt that’s true, the tip I apparently missed was that if you suspend the armor outside-down, REINFORCE those POS paper supports. I should have thought of that, but the disaster began there.
It didn’t take long for the weight of the ‘wet’ paper to cause the supports to bend, collapse, and even rip clear off. If anyone does this, be sure to reinforce the supports with either metal or plastic posts on top of the paper ones, or if you have the material, replace the supports completely. My first cup of mixed resin was wasted because it all dried while I attempted to re-establish the posts after they collapsed. Trying to tape posts back in place with hardening-by-the-second resin coated gloves on was comical. I eventually had to accept the lost session and re-group.
So here is the regroup: Parts suspended with wood and metal cross-bars. It wasn’t AS terrible after this.
Attachment:
20120812_091220.JPG [ 191.72 KiB | Viewed 9392 times ]
2nd problem was that I taped my pep pieces together (rather than glue). It didn’t take long for me to realize the fiberglass resin softened the tape and the resin didnt soak through the tape. It didn’t fall apart, but the resin that went over tape did NOT adhere to the paper underneath. It basically dried with air gaps under the tape.
It looked good on first glance.
Attachment:
20120816_150916.JPG [ 91.98 KiB | Viewed 9392 times ]
I haven’t decided if this next part is good or bad yet. With the first coat of resin on, next I used some spray adhesive. zapped the inside then laid out the fiberglass cloth. For the cloth, I decided to use a welding blanket, which is essentially uncoated fiberglass. Its THICK and heavy. It also slightly stretches, so it conforms to rounded edges while staying in one piece (so I thought extra strong, which actually was true). The bad part was I think I didn’t properly take into account just how thick it was, because I fear I didn’t completely “wet” the fiberglass. Again, in addition to the tape not adhering to the paper, now even the fiberglass cloth didn’t adhere to the paper in many areas!
The end result was indeed a HEAVY thick fiberglass shell, but all the paper from the pep is NOT touching it! I can literally peal it off.
Attachment:
20120812_172921.JPG [ 164.76 KiB | Viewed 9392 times ]
BUT, I have not given up. I am thinking I can still save this. I believe if I peel the rest of the paper off, I will still have the general fiberglass shell, which again, is quite strong. I will lose some fine detail, but the basic shape is very firm. I will do another coat of resin and cloth on the outside to smooth it out, then sand heavily. I believe I can salvage it, but I guess we'll see.
Im gonna move on to the shoulder bells, priming, and webbing for a little while though. I need a couple days away from fiberglass...