Covering an object with polyester

Covering an object with polyester has a number of important advantages: the object is strengthened, becomes water-resistant and is easy to colorize. Coating with polyester is therefore often applied to various products. This includes:

  • Coating the inside of a van to ensure it meets HACCP standards.
  • Covering a wooden object or structure so that it can be left outside for a long time.
  • Covering works of art such as statues so that they are strong enough to be placed outside.
  • Making custom parts of cars (adjusting bumpers, making custom interiors).
  • Covering carnival floats, on chicken wire, wood, foam, etc.
  • Covering ponds, swimming pools and roofs.

The methods of the above jobs are very similar, but we have created separate information articles about some topics. In this article we will discuss in general how to cover with polyester using a step-by-step plan.

We have also summarized the steps below in a video.

Step 1. Preparation 

Before you start, it is important that you determine which materials you need and/or whether or not an adhesive primer should be used. For Styrofoam coverings you need a special polyester resin. In the table below you can see what preparation you need for each surface.

Surface Pretreatment Comments
Wood Adhesive primer Coat wood all around
Concrete, stone Adhesive primer  
Styrofoam None   Use polyester resin for styrofoam
PU foam  None  
Papier Mache None Let the paper mache dry thoroughly before applying the polyester

Raw materials

We also have complete laminating sets for the polyester resin, fibreglass mat and hardener.

Tools:

Personal protection:

Step 2. Applying the adhesion primer

In step 1 you read that in certain cases (wood, concrete and stone) you must pre-treat the surface with an adhesion primer. The consumption of G4 adhesion primer is 200-300 grams per m2, depending on the surface. Apply the 1-component primer with a velor roller or brush. After approx. 1 to 2 hours the primer is dry and it can be coated with polyester. The polyester must be applied within 12 hours of applying the primer. So only apply primer if you continue with the polyester the same day.

Step 3. Applying the fibreglass with polyester

Pour the required amount of polyester laminating resin into a mixing cup and add 2% polyester hardener. Mix this together well. Then apply the resin to the surface with a fleece roller (nylon roller). This way, the glass mats that you are now going to apply will stay in place better.

Tip: only use 1.5% hardener at temperatures above 25°C. In cold weather you can dose a little more (for example 2.5%). Avoid working in bright sunlight. This way the processing time is optimal.

Tear the fibreglass choppend strand into pieces and place them in the resin. Then apply a layer of polyester resin over this with a nylon roller. For more difficult areas, such as corners, you can use a brush. The fiberglass mat must be wetted in its entirety. White spots have too little resin and shiny spots have too much resin.

Once an entire layer has been applied, you can deaerate the layer with a de-aeration roller. Gently roll over the surface with the de-aeration roller so that air bubbles are pushed out from under the laminate. This is an important part of the process.

Once you have properly vented the laminate, you can apply a second layer. Usually 2 layers of coatings are sufficient to completely cover the surface. With 2 layers of 225 gr/m2 you have a thickness of approximately 1 mm. With a heavier glass mat, for example 300 gr/m2 or 450 gr/m2, the surface becomes more stiff.

Tip: pour some acetone into a bucket and clean the bleed rollers with acetone after use. Remove the hairs with a brush. This way you can use the deaeration rollers more often.

Step 4. Finish with polyester topcoat

Polyester topcoat, also known as polyester varnish, provides a finish with a light roller structure. Once the polyester resin has hardened, coarsely sand the surface with 60 grit. This will remove raised fibers and small irregularities.

Pour the required amount of topcoat into a mixing cup. Do you work alone? Then do not create more than what you can process in 15 minutes. Now add 2% polyester hardener to the top coat. Mix both components well and pour the mixture into a paint container.You can easily apply the polyester topcoat with a fleece roller. Apply approximately 300-400 grams of topcoat per m2.

In the video below, Kees explains how to finish polyester laminate with polyester topcoat.

Step 5. Smooth finish with DD Paint

Do you want a smooth high-gloss finish of the polyester layer? First sand it until a flat surface is achieved. Then prepare a generous amount of polyester putty and spread it over the polyester. When the filler has hardened, you can sand the whole thing again. Repeat this process until the surface is completely flat and smooth again.

Then apply a layer of Double Coat DD Paint.

More information?

Do you still have questions or need advice after reading this article? Please feel free to contact our customer service team!

Product advisor
  • Expert advice
  • Superfast delivery with PostNL
  • Pay after delivery

Products used in this article

Product 1 of the 10

Do it yourself jobs with epoxy (DIY), polyester and PU foam!

Here you can find all 31 related articles on this topic. Mis je informatie om aan de slag te gaan met jouw klus? Neem dan contact met ons op.

Polyester for beginners Polyester for beginners
Polyester is a synthetic resin that hardens after adding a hardener. This process is irreversible, so polyester cannot be melted. Polyester does not rot or ru… More information
Epoxy for beginners Epoxy for beginners
At Polyestershoppen, you will find all the information you need about epoxy for beginners. Would you like to work with epoxy resin but don't you know where to s… More information
Polyester pond making | DIY Polyester pond making | DIY
Making a polyester pond has many advantages and is relatively easy to do yourself. If you make your own pond, you will save a lot of money! With the help of a g… More information
Polyester repair manual Polyester repair manual
Polyester is a material that is easy to repair with materials that are easy to process. An average do-it-yourselfer can easily carry out polyester repairs. On t… More information
Covering an object with polyester Covering an object with polyester
Covering an object with polyester has a number of important advantages: the object is strengthened, becomes water-resistant and is easy to colorize. Coating wit… More information
Covering an object with glass fabric and epoxy Covering an object with glass fabric and epoxy
Do you want to cast an object in epoxy? Then you are in the right place. In this article we explain how you can properly protect an object against external infl… More information
All about reinforcement materials (glass, carbon, aramid All about reinforcement materials (glass, carbon, aramid
When working with polyester and epoxy, reinforcement fibres are often used. There are different fibre materials that are available in different weave types. In… More information
This is how you repair a polyester camper roof! This is how you repair a polyester camper roof!
Over time, (hairline) cracks may appear in the polyester roof of your camper causing roof leaks. Repainting often does not give the desired result, especia… More information
Covering an object with carbon (overlay) Covering an object with carbon (overlay)
Making a carbon overlay with real carbon fabric (carbon) is not difficult. In this article we explain step by step how to achieve optimal results!  Suppli… More information
Finish metal and plastic surfaces with Double Coat DD Paint Finish metal and plastic surfaces with Double Coat DD Paint
You can give a metal or pastic surface a fine finish with Double Coat DD Paint. In this article we explain step by step how to do this. DD Paint is a 2-componen… More information
How do you make colour matching gelcoat? How do you make colour matching gelcoat?
In order to achieve an almost invisible gelcoat, the new gelcoat to be applied must have the exact colour of the surrounding gelcoat. It is often not possible t… More information
This is how you make polyester moulds! This is how you make polyester moulds!
If you want to make multiple polyester products, you can use a mould. You can then work faster and more efficiently. It is important that the mould is of good q… More information
Fix rotten wooden window frames with epoxy Fix rotten wooden window frames with epoxy
This guide will show you how to fix rotten wooden components of your window with epoxy. If you do it right you will no longer see that there has been wood rot!… More information
Finishing concrete countertops and sinks with epoxy Finishing concrete countertops and sinks with epoxy
Epoxy finishing concrete countertops, sinks, water ornaments and garden statues is a good way to get a smooth surface that is waterproof and easy to keep… More information
How to waterproof a wooden hot tub. How to waterproof a wooden hot tub.
Hot tubs are becoming increasingly popular. They offer the opportunity to relax in your own garden. Most hot tubs are made of wood. Wood insulates well and also… More information
Sealing EPS and XPS Styrofoam with polyester or epoxy Sealing EPS and XPS Styrofoam with polyester or epoxy
EPS (Expanded Polystyrene Foam) and XPS (Extruded Polystyrene Foam), better known by the names Styrofoam, Roofmate, insulation board or the like is an inexpensi… More information
Bakelite restoration. Cracks, cracks and missing pieces. Bakelite restoration. Cracks, cracks and missing pieces.
Bakelite is a hard, slightly brittle plastic. It has been widely used for steering wheels of cars and tractors, for radios, household appliances, switchgear and… More information
Repairing a plastic shower tray with polyester or epoxy Repairing a plastic shower tray with polyester or epoxy
Plastic shower trays sometimes become damaged through use, renovations or age. In this article we discuss the most common damages and show you how you can easil… More information
Venting casting resins | Tips & Tricks Venting casting resins | Tips & Tricks
After mixing silicone rubber, epoxy casting resin or polyester casting resin, a lot of air can enter the material. These air bubbles can lower the quality… More information
Polishing epoxy with polishing paste and a drilling machine Polishing epoxy with polishing paste and a drilling machine
A work of art, table or anything else you made out of epoxy resin, may get scratched over time. Epoxy resin scratches quite easilly, this is not a bad thin… More information
DIY | Making a cosplay shield DIY | Making a cosplay shield
How do you make your own beautiful shield that you often see on TV or at cosplay conferences? You can make one out of metal but that is very heavy and not eas… More information
DIY | Building epoxy aquarium and terrarium back walls DIY | Building epoxy aquarium and terrarium back walls
As an aquarium or terrarium fan, you will probably want to make your own back wall. The advantages are that a homemade back wall always fits exactly and looks e… More information
Give your bathroom a makeover with epoxy Give your bathroom a makeover with epoxy
Many Polyestershoppen customers have now renewed their bathrooms using epoxy. You can do various jobs in your bathroom with, for example, our epoxy floor coat… More information
Insulating a van with Froth-Pak PU foam Insulating a van with Froth-Pak PU foam
Do you want to convert a van into a camper van or use it as a refrigerated vehicle? Then you need to insulate the van well to limit the costs of keep the van… More information
Insulating your roof with sprayable Froth-Pak PU foam Insulating your roof with sprayable Froth-Pak PU foam
High energy bills? Time to do something about it! Of course, there are many steps you can take to make your home more energy-friendly. In many old houses or o… More information
How to cover a surfboard with carbon fabric and epoxy How to cover a surfboard with carbon fabric and epoxy
In order to achieve a perfect laminate and ideal fibre to resin ratio, the industry often uses the vacuum wet bagging method. This method involves applying a va… More information
Repair kits manual Repair kits manual
Is your shower tray broken or do you have a crack in your marble floor? Hiring a mechanic is often expensive and why hire a mechanic when you can fix it yoursel… More information
Bonding various materials Bonding various materials
Are you looking for the right products to bond different materials? We have a wide range of professional adhesives for bonding metal, iron, aluminum, wood, plas… More information
Tips and tricks for efficiently operating Froth-Pak insulation foam Tips and tricks for efficiently operating Froth-Pak insulation foam
In this article you can read everything about PU foam from Froth-Pak. We explain to you what the benefits of Froth-Pak are and what you need to process it. We h… More information
Wood stabilisation with Stabicure: the solution for durable and strong wood Wood stabilisation with Stabicure: the solution for durable and strong wood
Stabicure is a revolutionary method in the field of wood stabilisation. It is a process in which wood is impregnated with a special resin, also known as "c… More information
DIY | Make your own epoxy putty DIY | Make your own epoxy putty
Epoxy putty (filler) is a versatile and durable material that is often used to fill cracks, holes and other irregularities in various surfaces. Did you know tha… More information

Do you have a question?

Do you have a specific question? Call one of our specialists for free advice +3185 0220090