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How to Make a Hard-Shell Mold

The size and shape of a mold matches that of the surface, or plug, that it is based on. The plug can then be removed, leaving only the hardened shell. Fiberglass molds are often used when durability is paramount. Fiberglass molds use fibers embedded in synthetic resin to create an unbreakable hard-shell finish. Fiberglass is often used on cars and boats, as well as in model-building and art.

Things You'll Need

  • Mold-release spray
  • Gel coat
  • Water
  • Chopped mat
  • Resin
  • Bristled roller
  • Aluminum roller
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Instructions

    • 1

      Mist your plug with a coat of mold-release spray. Partall #2 is by far the most popular for fiberglass molds. Buff the spray well with a buffing pad. Apply four more coats in the same manner, with each coat being thicker than the last.

    • 2

      Spray a layer of gel coat onto the plug and allow it to cure for at least two hours. It may take up to four hours before the coat is fully cured.

    • 3

      Wet 1 ounce of chopped strand mat by dipping it in distilled water, or brushing the water on. Lay the mat on the surface of the plug, overlapping each piece slightly.

    • 4

      Apply the resin with a bristle roller. Coat it evenly. Use an aluminum roller to force the resin into the mat, and to smooth out the surface. Allow it to cure until it's hardened, and apply four additional layers.

Sculpture

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