Plaster cast
The plan all along was to fibreglass over the polystyrene model, adding strength and rigidity. It is a technique that is used to make canoes and other small watercraft. But want to know something funny? The liquid polyester that is used to set the fibreglass reacts with, and
melts polystyrene. Of course, I knew this from past experience but I bet y'all didn't see that coming!
The solution is to cover the entire model with a plaster-like substance, the kind that you use to smooth over cracked walls etc. It is cheap, readily available and easy to work with.
This is where the genius of the toothpicks becomes apparent: I was able to easily dismantle the entire model for plastering. In all I used
15 litres of of the stuff to coat the ACU from head to toe. I think the guy at the DYI store thought I was crazy. (
we think you are too, Micke -- Ed.)
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