The first big fiberglass project!

OK, we have finished the sanding... For now at least.  There will be more later, but at least every surface is flat and smooth to the touch.  All dust and debris is removed and wiped off the shell.  Now we get to another milestone in the Great Winter Project of 2016 (now 2017)!

The project requires two layers of fiberglass on the top and one layer on each side.  This is the largest application of fiberglass we have attempted so far.  First, some prep work to protect areas we don't want to get epoxy on.  We laid down a drop cloth inside and covered the quarter panels with plastic sheeting to prevent epoxy runs down the back.

Plastic drop cloth inside the shell

Protecting the quarter panels from what will become the hatch panel

Finally, the cats prove useful...In order to reach the lower panels during sanding, we raised the shell onto the boxes of kitty litter. 

We carefully unwrapped the fiberglass and rolled it over the camper leaving two inches on the edges to , careful not to have any snags in the fabric. 

Once we had the first layer out and over the camper, we have to smooth out the fabric.  The aim is to get the fabric flat before we add the epoxy so it bonds easily without us having to tug and pull it.  Luckily, Andi knows about fabric and how to manipulate the weave - a little education in fashion studies has unexpected benefits! Who knew? :)

Adding a second layer on top of the first

Two layers of fiberglass on and pulled tight and smoothed flat. Ready for epoxy goop.

CLC allows us an option to do the fiberglass stage in three separate increments.  First the top two layers, and then each side layer one at a time.  It is much easier to manage this step and would be very difficult - but not impossible - otherwise.  To do the whole thing at once would require at least three people together.

The edges of the first two layers run to about the mid-point of the quarter panels, and are feathered due to the cut of the cloth.  These will have to be sanded into a smooth edge before we lay the side cloth on top.  The sides will overlap the first two layers onto the top panel by about two inches, making a triple reinforced strip running the length of the camper from front to back.  This reinforced strip gives enormous strength to the camper and is where the add-on roof rack system can be installed. 

The lighting is a little dark... but after 24 hours of curing...it turned out awesome!  These pictures do not do it justice.  After being soaked with epoxy, the wood turned much darker and looks much closer to what it will become in the finished product, except the fiberglass weave can still be seen and felt.  It looks spectacular with a little sheen to it.  Much different look than just bare wood. 

Once all the layers are on and dried, a good light sanding all around is necessary to remove any small epoxy "pimples" - little sharp spots of excesses of epoxy that dried rough relative to the surrounding area.   Then we add two more coats of epoxy to fill in the remaining weave and tip out any air bubbles to leave a exceptionally smooth finish.  Can't wait!