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Old 05-23-2010, 02:38 PM   #6 (permalink)
Bicycle Bob
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Fiberglass cloth will print through and do all sorts of irregularities if messed with when the resin is green enough to accomodate a 3-D shape. You can use stretched membranes to improve the finish on male shapes, but I've not heard of a vacuum bag being used to give a molded part two good surfaces.

For putting a nice skin on foam, here's a new spray-on coating:

Industrial Polymers Corporation-StyroSpray

I've also had good success producing mold bucks (one-use master shapes) from foam covered with easy-sanding wall filler and then painted. I had a mix of latex paint, spackle, and microbaloons that sanded as easy as regular 2-lb insulation foam, but could get a hard, shiny surface by being coated with either PVA or Shellac and polished as usual.
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