Okay, I have some specific questions about the various fiberglass fabrics and epoxy resins:
Fiberglass Cloth
Epoxy :*Epoxy Resins and Hardeners
For the skin on my 1/4 scale CarBEN model, what weight and type of fiberglass fabric would be best?
4oz plain weave
For the full size shell of the CarBEN EV, what weight and type of fiberglass fabric would make sense? For the bottom and the surfaces where suspension components will be attached, I am thinking that using a heavier fabric will be good.
Use plywood or hardwood buried in multiple layers of glass cloth and silica filler for hard mount points. You can use 6oz plain weave for this as well as anything else, although a biaxial or triaxial woven roving may provide more bulk and strength. I would just use plain weave until you know what you are doing and can design a special layup.
To make smooth wheel covers, or wheel strakes, or belly pan -- the same question?
Thin plywood covered with one layer of lightweight cloth, 4 oz would work.
I know I need to use epoxy resins since I am using EPS foam to build up and carve the forms; but should I use the medium set time thin epoxy, or the slow, or the fast? The outside will have the skin first, and then I'll skin the inside, as well. The inside of the hood area, the inside of the battery compartment in the floor, and the front and rear wheel wells and skirts, also will be fiberglassed.
It is very difficult to get a smooth finish when covering foam with glass cloth. I would suggest testing the following for nonstructural parts: Sand the foam to shape. Cover with clear epoxy, let cure. Spread glass bubble filler over any rough spots, sand. Paint. I don't know what EPS foam is so I may be way off on this. Plan on using a lot of glass bubbles and doing a lot of dusty, dusty sanding to get glass cloth smooth. Take anything of value out of your workshop, it will be destroyed by the dust.
Should I get the 1oz pumps? What applicators, rollers, gloves, masks, suits, etc. would you recommend?