- Using the plastic mould (army hat we vacuum formed) coat the inside with Mirror Glaze by dabbing a tissue into the pot and rubbing it inside the hat.
Leave for 10 minutes. Buff this layer with more tissue and repeat this process a further 2 times.
- Then spray the inside with mould wax.
- Mix together 100g of polyester gel coat with 1g of liquid hardener. Use this ratio when using hardener; 10% of hardener to the amount of substance you're mixing it with e.g 100g of substance = 1g of hardener. Use gloves, goggles and mask when mixing these!!
- Add in 3/4 (three quarters) of a cup of iron powder and mix. Coat mould in a layer of this with a brush. Leave for 1 hour.
- Mix 100g of lay up resin with 1g of hardener. Add no more than 5% of the weight of the mixture of black pigment. Use gloves, goggles and mask again!!
- Coat the hat with a layer of this with a brush.
- Tear fibreglass into small squares and start laying them on the inside of the mould. Dab this down with the resin and brush until you cover the whole inside. Repeat this.
- Tear up sheets of fibreglass (finer than the last lot of fibreglass, more smooth to touch) into small squares. Layer these on the inside of the mould and dab down again with the resin and brush.
- Leave to dry. When dry take hat out of mould and cut off excess edges. Sand the edge of the hat down to make it smoother.
- Using wet sandpaper, sand the hat until it has a grey/ silver look to it.
- T- cut the hat by dabbing tissue into the substance and rubbing over hat in a circular motion. Then get some wire wool and scrub over the hat. Repeat at least 3 times.
- Cover in a layer of Covent Garden primer (so that paint will stick to the hat)
- Paint hat a khaki green colour inside and out. Then add details such as mud etc to the hat using brown paint.
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