Building a Fishing Kayak Cooler #7: Fiberglassing a Panel and Taping the Outside Seams

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Blog entry by DustyMark posted 05-03-2019 01:59 AM 744 reads 0 times favorited 2 comments Add to Favorites Watch
« Part 6: Making the Top Part 7 of Building a Fishing Kayak Cooler series Part 8: Installing the Ceiling and Feathering the Fiberglass Tape »

Fiberglassing a Panel

Fiberglassing an individual panel is pretty simple.

Drape an oversize piece of cloth over the panel. Pour epoxy on it.

Spread the epoxy with a scraper to fill the weave, but leave no puddles.

The weave of the cloth will remain prominent after the first coat.

Once the epoxy reaches green cure, trim edges with a razor and apply another fill coat of epoxy. It may take three coats total if you’re going for a glass smooth finish. The inside of this cooler only gets two coats.

Taping the Outside Seams

Stitch and glue construction gets strength from being taped both inside and outside the seams.

Precut the tape for all the seams..

Soak the tape before applying it to the cooler. This makes it a lot easier to wet out the cloth, especially on vertical surfaces.

Tape is applied and needs more epoxy.

Tape is wetted well for a first coat and the raw wood has a seal coat of epoxy as well.

Next Steps

1. Trim the fiberglass edges.
2. Feather the edges of the tape with an orbital sander.
3. Give the cooler another coat of epoxy.
2. Install the ceiling piece.

-- Mark, Minnesota

2 comments so far

View robscastle's profile


7238 posts in 3012 days

#1 posted 05-03-2019 11:29 AM

I hope one of the Next Steps involves making a lid for the cooler.
I dont want to be reading about you being missing 17 miles from Whitefish Bay.

-- Regards Rob

View DustyMark's profile


449 posts in 2878 days

#2 posted 05-03-2019 01:29 PM

I should put my name in it so they can ID me! I designed it for 3/16” of compressed weatherstripping under the lid. I ordered some 3/8” thick by 3/4” wide that should arrive tomorrow. Once I confirm the compression, I’ll know what size to make the lid. This is a tricky step…

-- Mark, Minnesota

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