Re: Spartan Laser Metal & Fiberglass Airsoft Prop (Fully Functioning Electronic Repli
Thanks for the info. What kind of fiberglass mat did you use? And how exactly does 2 layers of mat translate into thickness in inches or mm?
I use a standard 3 ounce mat. I don't know what that measures exactly, but it's a fairly heavy mat. There is also 1.5 ounce mat out there--easier to work details, but wants to pull apart easily when trying to work larger pieces. The 3 ounce is basically a double layer of 1.5 ounce. You can pull the layers apart if you need to thin it.
I use the cheapest polyester resin I can find. DO NOT use epoxy resin with ordinary mat. The binding agent in standard mat corrupts the catalytic process of the epoxy, preventing it from curing. If you want to use epoxy resin (much more expensive than polyester, but no odor), use cloth or find the special mat for epoxy resin.
For my parts I want to use in airsoft, the double mat gets me a finished thickness of 1/8 to 3/16 inch thick. It's easily a 1/4 inch in the corners, but that's where I need the strength not to chip or splinter. Remember, there is no advantage to using any more resin than it takes to saturate the cloth or mat. It's brittle and adds weight.
Honestly, the two layers is a bit much for cosplay. I would use only a single layer in a prop weapon or costume. I might double or even triple some narrow (1.5 inch) strips around the interior edges of a costume piece for strength and to allow rounding the edges. For a prop weapon, your target weight should be under 6 pounds if you plan to carry it all day in costume. My Spartan laser weighs 14 to 15 pounds with the airsoft gear removed. I can carry it all day at a con (out of costume), but end exhausted. In a costume, you carry weapons much further from your chest and excess weight is killer. I'm good for only an hour max with the Splaser in costume. On the airsoft field, the Spartan Laser is 22 pounds combat loaded. I run a very light loadout for that reason--a canteen, extra BBs (in my frag grenade), and a small sidearm (good 'ol 1911).
So what are you looking to build?
Redshirt