Fibreglassing the hull.

18 September 2022

I purchased a product called Botecote, which is a far safer alternative than standard, solvent-based resins. Over 300GSM fibreglass mat, (kindly donated) it has a good coverage, (5m2 per 1Litre) and a 45 minute pot-life. The purchase also included a drum of filler for low spots afterwards.

It’s also low allergy, low toxicity, among other features of this more modern technology in resins.

Here’s the link if you want to check out the product.

I started on the underside of the starboard wing for practice, as it is a new product to me and I am a little out of practice since my last big fibreglassing job.

The wing has some compound outside angles and some recesses, so this was a good test to see how much I could get the mat to mold to these shapes.

22 October 2022

Now that both wings are fully covered, it’s time to move onto the rest of the fuselage. I started at the nose, as I knew it would be a good test, as there are a lot of inside and outside curves and corners to mould the fibreglass around. Getting the glass to stick to upside-down surfaces was easier than I thought it would be. after that it was a matter of covering the avionics recesses with cardboard, before continuing to glass down the rest of the fuselage.


30 November 2022


I got all the intakes done inside and out, plus about a metre of the top nacelle and the port nacelle. Now I’m out of resin, saving up for the next batch to finish it. There’s still a top coat to go, some body-filler, and sanding with the big orbital, before a final paint.
In the meantime, I thought I’d try to make the RCS ports look a little more technical with some detail in the holes.
26 May 2023
All the fibreglassing is done now, so after running over the entire hull with with an orbital sander, it was on to the filling. Botecote resin is now mixed with a light-weight filler powder to make a putty that is applied with a broad plastic spreader. It fills all the micropores in the fibreglass matt and makes the entire thing smooth and waterproof. Like car bog, (bondo in the US) it can be used to fill low points in the surface, but as it has such a long cure time, it tends to sag if you lay it on too thick. My plan is to cover the entire hull, block it with a long-board sander, then start the filling process with bog.
There’s still a lot of work to do before I paint it. Preparation is everything.
31 July 2023
I’ve finished with the resin coat and now onto the sanding/bogging/sanding/bogging until it’s all smooth ready for painting. While I was at it, I fabricated and installed the rest of the RCS ports.

4 thoughts on “Fibreglassing the hull.

  • Michael Merino

    Baz, I can’t tell you how cool your project is! I only wish it were in the US so I could see it first hand. Keep up the phenomenol work! I can’s wait to see it finished. Mike

    PS: I’m not a kid but an adult BG fan myself!

  • Steve Liptak

    Beautiful! It’s like a new species being born! What would estimate the total weight is now?

    • BuildsByBaz

      About 850kg mate.


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