MOD - Trim Servo Cover

I started attempting to make a trim servo cover out of fiberglass. I cut out and carved a mold out of blue foam some weeks ago and finally got around to trying to fiberglass it. Did some research online about the process. I had to protect the foam from the resin as it would melt it. So, several articles suggested that you cover the foam with plastic wrap (Saran Wrap). I did, and proceeded to layup the fiberglass and resin doing two layers of pretty thick fiberglass weave. Unfortunately, I didn't get enough hardener into the resin on the first layer. It didn't set up well. The second layer I did much better and it did set. However, the first layer allowed some resin to seep through the plastic wrap to the foam melting it.

So, my first attempt melted my mold but, the second layer did set so I think I can use it as the new mold. I also learned that I'll need three good layers of fiberglass to be stiff enough for a cover. This first cover was a little flimsy so I decided to fill it with expanding foam to stiffen it enough to use as a mold. This worked well and after letting it set up over night it is plenty stiff to use as a mold.

Wrapped in plastic, hot glued in place

Hand forming the fiberglass mat before adding resin

First layer of glass and resin

Second layer of glass and resin

Part after curing and cleanup.

Visible air bubbles from incorrect resin mix on 1st layer.

Adding expanding foam, weight to hold it down while the foam expands out the rear

Foam cured, cleaned up ready for round 2...