Use of gloves, breath mask and eye protection is mandatory. The fume hood light and exhaust system must be switched ON while working.
Hand layup requires a clean flat surface as the working surface; it forms the bottom texture of the plate.
A clean plastic sheet is placed on the flat surface and waxed on the surface with normal car polishing wax, for easy removal of the plate.
The fibers are cut (both Mat and Woven fibers). Care should be taken when handling the fibers. Improper handling will cause damaged and distorted fibers.
The tools for hand layup like brush, serrated roller should be clean and non-sticky.
The resin is mixed in a beaker with the proper ratio (Inside the Fumehood!), as given in the material safety and data sheet. The quantity of the resin depends on the size of the plate made. Usually 400 ml total is enough for a plate of size 5"x 11" x 7 layers.
A first coat of the resin is applied on the waxed plastic sheet. The Mat fiber layer is placed on top of that and the resin is applied using the brush. The serrated roller is used to even out the resin and remove any entrapped air in the resin.
The woven fiber layer is placed on top of the first layer, and the above is repeated.
Further layers are piled up on top of others with resin and serrated roller is used to drive the air out and to ensure proper compaction.
After the final layer (Mat always) is laid, it is covered with a waxed plastic sheet, and a flat plate is placed on the top with a weight to ensure a good surface.
The whole set is allowed to sit for the required time for cure (In case of polyvinyl, it is about 8 – 10 hrs before handling).