Fiberglass Armor Construction: Remove from the Mold
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Removing the Piece from the Mold

This is always one of the most fun parts for me. It is very easy and rewarding. Once the piece is cured you will take it out of the mold. When you do so be careful of any sharp edges on the fiberglass. I can’t count how many times I cut my hands with sharp edges where the fiberglass stuck out from the end of the mold. If you have some thick leather gloves this would be a good time to use them. If not try to at least use a pair of latex ones, it may save you from some unpleasant splinters.

Chest armor right after being taken out of the mold. Note all the bits around the edges that need to be trimmed and all the ripples and bumps and defects on the surface that need to be sanded out.

Depending on the shape of the piece you may be able to just pull it right out of the rubber mold. If it has undercuts or does not want to pull right out you can first remove the plaster support mold and then you should be able to peel the rubber mold right off. Just like when the rubber mold was taken off of the model.

Once you have pulled the piece out take a close look at it. You especially want to look for bubbles, divots and thin areas where a big bubble is just below the surface. If you find any of these you will want to fill them in. If you are planning on putting on a layer of gel coat the gel coat can be used to fill in these places. If not you can quickly mix up a small amount of resin to fill the gaps. Be sure to wash off any Vaseline or other mold release first. If the resin does not work for filling these gaps I have heard of people using Bondo for this purpose. I have always used the gel coat option myself, so I can’t say much about the Bondo solution, but it seems like it would work.

If there are any thin areas in the cast you can still lay another layer of fiberglass on the back to reinforce that area.