Page 2
Applying Resin

Here's me, applying the resin.  I chose to paint it on with a cheap brush. Make sure to get the inside as well as the outside. I chose to mix the resin in some cheap aluminum pans, I think they were 3 for $1, and I reused them as much as possible.

Get it nice and soaked. The more thoroughly soaked it is, the harder it will be.

Make sure to get all edges really well.... try to get the entire piece, inside and out, all at the same time. That way the entire piece is saturated at the same time and will harden better than if the outside has dried, and then you apply the resin to the inside... it will dry in 2 seperate layers and will not be quite as strong.

If you soak the brush in acetone between pieces, you can salvage it. otherwise, buy the cheap ones and just grab a new one each time.

Once it is hardened, this is what you should have.  A somewhat rough finish, but in the exact basic shape you wanted.

Mine dried extremely hard, and the fleeced swelled up at almost 1/4" thick, which is enough for this piece. If your did not get this thick or hard, you may need to reinforce it with fiberglass matting. I suggest laying the matting on the inside if possible, that way you will still have a nice shape on the outside, since there is less sanding with the fleece being your outermost layer.

Next, I ground down all the high spots using a dremel and a sanding bit.  The edge where the fleece met the plastic was a very rough edge. You can grind away at some of that to help smooth it out, but don't go too far or you'll go through the fleece and/or really weaken that seam.

Notice how I scuffed the plastic everywhere the superglue, resin, and body filler will be...
to help them adhere better

Resined Fleece vs Ready to Prime

I then scuffed the surface really well with the 50grit sand paper to help any high spots and smooth it out just a bit

First session of sanding done

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Body Filler