A chair for daydreaming. Structure made of fiberglass, upholstered with Knoll wool felt.

white styrofoam 3'' thickness
9 oz satin weave fiberglass 38'' width (20 yards)
50'' width honeycomb shaped coremat (4 yards)
314 Tap plastics epoxy resin (1 gal) +143 hardner (1/2 gal)
Cal-O-Sil glass microbead filler
1'' thickness 12'' width high density foam (8 yards)
Knoll felt, ivory (6 yards)

Clear packaging tape
Mold release spray
Vinyl specking
Bondo
Montana Black acrylic paint
Spray adhesive
Measuring tools
Scrapers
Sander & sand paper
etc.

Step 1: Inspirations

Find inspirations and put them in a mood board.

Step 2: Fiberglass Chair Body

Build a model of the chair in Rhino and export the section drawings. Cut styrofoam sheets according to the section drawings, glue the styrofoam sheets together, and use a hot wire cutter to round up the shape of male mold. Speckle to make the surface smooth.

Apply clear packaging tape and mold release to the mold surface. Cut fiberglass fabrics and coremat ready before starting to mix epoxy resin. Here the layup is composed of 3 layers of fiberglass, 1 layer of coremat, and 3 layers of fiberglass. A layer of peel-ply is added on top to make the top surface smoother.

After cured pull off the fiberglass body off the mold. Sand the surface of the body smooth. Apply bondo if needed.

Step 3: Add Legs

Cut 4 legs using styrofoam and sand them to tapered cylinders. Attach the legs to the fiberglass chair body using glass micobeads mixed with epoxy resin. Add wood feet to the styrofoam legs to provide more support. Lay up fiberglass fabrics (8 layers here) around the legs.

After cured apply bondo and sand down the legs so that the surfaces are smooth and the feet are on the same level. Prime and paint the legs.