Hi Bob,
I will try and explain the process without using brand names as I think they will differ over there in the USA. I have used a good quality aviation grade glass, epoxy resin and hardener.
1) when you trim your window openings, leave about 5 mm extra around the rear window openings as well as the door window openings. This will leave you with a slightly wider ring and more that can be trimmed away if needed.
2) Sand around the window openings, on the inside in order to flatten the really rough parts. A 120 grit will be ok.
3) Apply release wax on the insides all around the openings. The right way to apply it is to wait for about 15 minutes, polish it slightly, apply again and wait for it to dry again. Do this about four times.
4) Prepare your glass by cutting it in strips of about 100 mm wide. It is very important to cut your glass at 45 degrees to the weave. If you do this you will have strips of glass with a very good ability to stretch in all directions and this means that it will "drape" nicely around corners and into curves without having to cut. Also prepare strips of peel tape the same way.
5) Mix resin with flox and apply into the sharp corners (windscreen and door windows) in order to reduce the radius somewhat. this can be done by putting resin mixed with flox into a small zip bag, cut one corner and squeeze out as needed. Gently flatten resin in corners with a small brush.
6) Next wet the whole area around the openings.
7) Then apply about 4 layers of glass, wetting out each layer properly. Going around in circles and not having the joints in one place is good.
8) Apply one layer of a fine peel tape on top of the glass layers. Try to wet it out with the resin already in the 4 layers. If it is too dry in places, ad a bit of resin. Spend some time trying to make your peel tape as smooth and flat as possible. Cutting the peel tape at 45 degrees as well, is a must in order to make it drape properly.
9) About 10 hours later pull of your own close out rings!
In summary - most of us hate fiber glass work, but a few hours spent with someone who knows fiber glass was really worth it and changed my mind. Thanks Chris Adrian!
