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Old 12-17-2010, 04:00 PM   #1
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1968 20' Globetrotter
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Custom fiberglass shower pan

I just finished an shower pan for the back corner of the Globetrotter and thought I would share what I learned.

I took a paper template of the curved wall and determined the best place for the drain. I made the plug mould from styrofoam and smoothed it with drywall compound. I decided to make a simple one-time mould and put more of my effort into the finished pan than the mould.

Click image for larger version

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I covered the plug with poly and laid up the fiberglass using polyester resin. First mistake! The heat from the resin curing melted the mould causing the glass to sag in a number of places. This seems to be a new problem...many sources said this method should work fine as long as the poly doesn't leak solvent. It didn't, but the stryo still melted. I'm wondering if this is a new 'green' formula styro??? Who knows.
If I was doing it again I'd pay the extra money for epoxy resin to avoid the problem and save a bunch of finishing time.
The pan came off the plug OK . I added the front lip and sanded and bondo-ed to get a smooth surface.
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Once I had a surface I was happy with, I applied two coats of white Gelcoat and sanded up to 600 grit. I didn't polish the finish so it wouldn't be too slippery.

The final result ...Click image for larger version

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Old 12-17-2010, 04:06 PM   #2
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looks good. What did you use for a pan? What is the front piece made out of?

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Old 12-17-2010, 04:10 PM   #3
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The pan is the part I cast in fiberglass off the mould...the front lip is a 2 x4 ripped down with rounded edges.
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Old 12-17-2010, 05:13 PM   #4
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Thanks for posting this, Ian.

I'm at the same step with mine and have been kicking this back and forth. My old pan is stainless, but would need to be reworked, and I've been thinking about making one using epoxy for the last week or so.

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Old 12-17-2010, 05:26 PM   #5
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Really nice work!

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Old 12-18-2010, 09:14 AM   #6
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Polyester resin will melt styrofoam. Sal.
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Old 12-18-2010, 11:23 AM   #7
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Originally Posted by noreen View Post
Polyester resin will melt styrofoam. Sal.
Effectively, yes. There's actually a solvent reaction; it's more of a dissolving action. Polyurethane foams are supposed to be ok.

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Old 12-18-2010, 03:15 PM   #8
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Impressive! Thanks.
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Old 08-22-2012, 07:47 PM   #9
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Hey, I want one of those!
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Old 04-27-2014, 09:46 AM   #10
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Looks great! I might steal your method.
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Old 04-27-2014, 10:06 AM   #11
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Yeah polyester resin will eat styrofoam. Wax paper is a good separator. It's not the heat of the cure, but you can cut down the heat by adding less catalyst for a slower cure. One trick for a smooth finish to the fiberglass is cover the fiberglass with an layer of wax paper until it cures.

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