How to Make a Fiberglass Mold from Foam Board

By Society & Culture & Entertainment Last updated Thursday, May/23/2024

1). Apply a coat of acrylic sealant to the foam to prevent absorption of the mold-making products. Acrylic sealant typically comes in a spray can like spray paint, but can be found in pots as well. Allow to cure for at least an hour or until no longer tacky.
2). Spray on five coats of mold-release spray on the foam. The first coat should be applied lightly, then buffed. Apply a heavier second coat and buff again. Continue this process for five coats.
3). Lay pieces of chopped strand mat on the surface of the plug, making sure all areas are covered and each piece of mat overlaps slightly. Wet the mat with water using a sponge.
4). Using a roller, apply the fiberglass resin. Work it into the matting while applying. Smooth any air pockets with a flat, aluminum roller. Cure until hard and apply another layer of mattings and resin. Your mold should be four to five layers thick for most purposes.

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