Fiberglass panels are versatile, durable, and surprisingly easy to make at home. Whether you're a DIY enthusiast looking to repair your boat, install custom interior panels, or enhance your construction skills, creating fiberglass panels from scratch can be a rewarding project. This guide will walk you through everything you need to make high-quality fiberglass panels yourself—from understanding their uses to mastering the fabrication process.

By the end of this post, you’ll know exactly what materials to gather, the steps to follow, and tips to ensure a professional-looking result.

What Can You Use Fiberglass Panels For?

Fiberglass panels are an essential material for various DIY and professional projects due to their lightweight nature, strength, and weather resistance. Here are some practical uses to inspire your project:

• Automotive Repairs: Fiberglass panels are famously used to repair or create car body parts. They’re lightweight, yet tough enough to endure wear and tear.
• Marine Applications: Boats often require fiberglass panels for repairs on hulls, decks, and other surfaces exposed to water. These panels resist moisture when a vinyl ester or epoxy resin are used. The panels can be easy to shape.
• Decorative Purposes: Use fiberglass panels to make decorative features, such as textured wall panels or unique furniture pieces.
• DIY Hobby Projects: From building bike frames to custom speaker enclosures, fiberglass panels are a favorite of hobbyists for their versatility.

Now that you're excited about the possibilities, let's discuss how to make these durable yet lightweight panels yourself!

Materials Needed for a Cored Fiberglass Panel

Creating fiberglass panels requires a few carefully selected materials. Make sure to gather the following before starting your project:

Main Ingredients

1. Fiberglass Cloth, 1708 Knitted Fiberglass or Chopped Strand Mat: This serves as the structural reinforcement for your panel. Choose between woven fiberglass cloth (for a smoother finish), knit 1708 (for sturdiness) and fiberglass mat (for thicker panels). 
2. Resin: Polyester, vinyl ester or epoxy resins will act as the binder. Epoxy resin offers the most durability and strength, though it’s generally costlier. Epoxy resin is also not compatible with chopped strand mat. If you are using mat, use polyester or vinyl ester resin.
3. Core Material (Optional): For cored panels that need extra thickness and rigidity, use materials like coosa, foam, balsa wood, or honeycomb structures. 
4. Gel Coat (optional)- Only use this if your resin is a polyester or vinyl ester. If you are using epoxy resin, you will need marine paint or other.

Tools and Accessories

4. Mixing Cups and Stir Sticks: You'll need these to mix your resin and hardener.
5. Hardener or Catalyst: Combine with your resin to cure (harden) the mixture.
6. Brushes or Rollers: Used for applying the resin evenly.
7. Mold Release Agent or PVA: Prevents the resin from bonding to your mold during curing.
8. Mold or Base Surface: A flat or shaped surface where you’ll layer the panel. Plexiglass, glass, or polished wood coated with a release agent works well.
9. Sandpaper (Various Grits): For finishing the surface.
10. Protective Gear: Gloves, goggles, and a respirator are essential to protect yourself from fumes and irritants.

Got your gear together? Time to get hands-on!

How to Create the Fiberglass Panel

Follow these simple steps to craft your custom fiberglass panel with ease. Precision and patience are key to ensuring high-quality results, so read through the process carefully before jumping in.

Step 1: Prepare Your Work Area and Surface

• Set up a well-ventilated workspace to handle resin fumes safely. 
• For your mold or surface, apply a release agent and/or PVA generously across its surface. This ensures the panel doesn’t stick after curing. You will need several layers of paste wax, if using.

Step 2: Cut and Arrange the Fiberglass Layers

• Measure and cut fiberglass cloth, knit biaxial or chopped strand mat to fit your mold. Cut multiple layers depending on the thickness you want. 
• For cored panels, cut your core material to size as well.

Layer the fiberglass to the side of your workspace in the order it will be applied. Alternating patterns (e.g., vertical and horizontal weaves) may improve strength.

Step 3: Mix Your Resin and Apply the First Layer 

• Follow the manufacturer’s instructions to mix your resin or gelcoat with hardener. Be sure to work quickly to avoid the mixture curing mid-process.
• If using a gelcoat, you will start with a good layer or two of gelcoat on the mold release prepped surface. You will want to use an unwaxed gelcoat so you don't have to sand between layers. It can be applied with a brush, roller or spray gun. Once cured, follow up with resin and fiberglass.
• Use a brush or roller to apply a thin resin coat directly on the mold or base layer if you skipped the gelcoat layer. If you used gelcoat then you don't need a base layer. Place the first layer of fiberglass onto the mold and press it down to remove air bubbles and creases. 

Step 4: Add More Layers

• Apply a coat of resin over the first sheet of fiberglass. Then position the next layer of fiberglass cloth or matting over it and press down evenly.
• Repeat this process, curing in between layers, until your desired number of layers is complete. For cored panels, place the core material after a few fiberglass layers, encasing it in resin before continuing with more fiberglass layers.

Pro tip: Use a finned roller to help eliminate trapped air, get rid of excess resin and ensure the layers bond smoothly.

Step 5: Allow the Panel to Cure

• Leave the panel to harden for 24 to 48 hours. The curing time depends on environmental factors such as temperature and humidity, as well as the type of resin used.

Patience is crucial here— rushing this step may lead to imperfections.

Step 6: Remove and Trim the Panel

• Once fully cured, carefully remove the panel from the mold or off the surface. It should pop off easily thanks to the release agent. 
• Trim any excess edges with a dremel tool, jigsaw, or sandpaper.

Step 7: Finish the Surface

• Sand the panel using progressively finer grits of sandpaper for a smooth, polished finish. Optionally, add a gel coat or paint for protection and aesthetics.

And just like that, you’ve created your very own fiberglass panel!

Want to see a video on creating fiberglass panels? Watch Capt. Joe on Fish Bump TV! He goes through the whole step by step process. You can watch here- https://www.youtube.com/watch?v=7GA1I5fjD1E

Craft Your Projects with Confidence

Making fiberglass panels yourself is a highly rewarding process that gives you complete control over your materials, design, and quality. Whether you’re repairing a boat or tackling your latest DIY hobby, these skills will serve you well in countless projects.

If you're ready to get started but feel unsure about choosing materials or tackling the process, don’t worry—resources abound for beginners. Explore local hardware stores, join online DIY forums, or take inspiration from fiberglass crafting communities.

Now, it’s your turn to make something amazing. Gather your tools, don your safety gear, and bring your ideas to life!