How to Create the Mold

• 1). Design the plug you want to use for your mold on a piece of paper.
  
  
• 2). Carve a Styrofoam block according to your design. Using 180-grit sandpaper, sand the foam to smooth the rough edges.
  
  
• 3). Cover the Styrofoam with Bondo thoroughly and allow it to dry two to three hours. Once completely dry, sand the Bondo until it is smooth.
  
  
• 4). Spray on the polyester primer and allow it to dry. Once it is completely dry, sand the structure using 220-grit sandpaper. Continue to sand the structure using finer sandpaper until you are wet-sanding with 1000-grit sandpaper.
  
  
• 5). Leave the mold to sit for three days, adding a layer of wax each day. On the third day, add three coats of tooling gel. Once the tooling gel coat has a tacky feel, you are ready to lay the fiberglass.
  
  
• 6). Brush resin into the mold. Separate the fiberglass strands in the fiberglass mat and lay on top of the resin.
  
  
• 7). Run the roller over the fiberglass to smooth out the surface and eliminate any air bubbles.
  
  
• 8). Soak additional fiberglass in resin, and add a minimum of three layers of fiberglass to the structure. Allow the fiberglass to dry.
  
  
• 9). Run a razor blade across the surface to remove any fiberglass overhang. Use the wooden stick to remove the fiberglass object from the mold.