Quote:
Originally Posted by Vekke
When using hand layup the structure wont become so stiff as when using vacuum pressure to suck the resin and pressure to push it againts the tool.
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"Vacuum pressure"? What's that? No such thing! There's vacuum OR pressure.
Which it is depends on if it's relatively higher or lower than ambient pressure.
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I'm with the rest on not relying on glue to provide structural strength with fiberglass. I'd paint a coat of epoxy over the foam first, let it cure, then sand it to reveal any low spots. Mix more epoxy, add microballoons and use that as filler. If you're going to use this as a plug to make molds, save yourself major headaches by making it as fair a surface as you can now.
For attachment points you'll want the glass and resin quite thick and gently tapered to the thickness of the main skin area. Metal tubes or threaded inserts are also a very good thing for attaching stuff to composite structures.
Don't make sharp corners in stressed areas or near areas subject to vibrations.