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There has been a small but obnoxious rain leak in the aft cabin of my small sailboat. It looks like the source is where the outboard motor control cab...
First thing you need is a mold! Use your imagination! This one is a soda bottle (filled with water to hold shape) Three layers of glass cloth were la...
After cure, the molding is rough trimmed with shears.
Here the flange is being laid up. Several short pieces of glass cloth (small scraps) were used to form the flange. Then a couple more layers of cloth ...
Wet out the covering layers and cover the layup with plastic wrap (epoxy won't stick to it). The wood pieces press the flanges to make it nice and fl...
When cured the plastic can be peeled off very easily - but the resin wicked up under it leaving a pretty ugly surface. Don't Panic! We are not done...
Rough trim to get rid most of of the excess flange...
Grind off the excess resin that was clumped up by the plastic wrap... Dremel tool with a 1/2" sanding drum. Or just a stick with 60 grit sandpaper g...
Now we can trim the flange to final size and shape... Looks a little better now, doesn't it?
Traditionally, fiberglass parts are coated with "gel coat", a wax rich polyester resin. Gel coat is thick, heavy and brittle, so it doesn't take a lot...
In this Instructible I made a part for a boat. But the basic ideas and techniques can be used to make ANYTHING from a blue water yacht - to space cra...
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![[Video] Mixing Polyester Resin](http://cdn.instructables.com/FO5/CP3K/WDFEZ7BGP9V/FO5CP3KWDFEZ7BGP9V.SQUARE.jpg)
![[Video] Part Making](http://cdn.instructables.com/F87/FLXY/F0H63OGW/F87FLXYF0H63OGW.SQUARE.jpg)
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