Glassing an airplane
I would suggest the following:
Do not use polyester resin. The hardener for polyester is very dangerous. one tiny drop in the eye and the eye will eventually be useless. You cannot wash it out quickly enough to prevent the damage. Polyester will not cure over some glues. The smell will hang around for weeks.
Use a good quality epoxy resin that is fairly liquid and try to get a fairly slow hardener. Some hardeners start to set up the resin after twenty minutes or so. this is too fast and does not give you enough time to work it. Avoid thinning the resin with anything. It can create cure problems and affects the strength.
Use about 3/4oz glass cloth. this cloth is fairly fragile and will need carefull handling. you will be adding weight to the airframe, but the weight will not be in the cloth. It will be in the amount of resin you leave on the airframe.
I will assume the airframe is sanded to the smoothness of a B.B.
Start with the wing. one side at a time, it is the easiest. I use one piece of cloth for each panel. Cut it with about a 1/2" overlap all round. Lay the cloth on the wing along with any center section glass that is to be applied. So now the whole top of the wing is covered with dry cloth. Mix up the resin and pour some on the centre section. Very carefully. so as not to wrinkle the cloth squeegee the resin through the cloth out to the wingtip. I use a flat piece of 1/16 ply about two inches wide. Then squeegee the resin chordwise. Do this for the whole wing. Smooth the cloth as much as you can and remove as much resin as possible but at the same time thoroughly wetting the cloth. Excess resin can be returned to the cup. When I have finished this part I then lay some toilet tissue (The absorbent type) on the wing for a few minutes to soak up any excess resin, then pel it off. When this has all cured sand off the excess cloth and repeat for the wing otherside.
To give you some guideline. On a 500 sq in. wing with the glassing all finished I have added about 3 1/2 ozs weight.
The fuselage is basicly the same procedure. You will have to decide yourself whether to do it in four strips or one large piece. I would suggest strips for the first time.
You now have a weave finish that has to be filled. Another coat of resin would do this but the weight will really go up. I use a lightweight spackle compound. I get a blob of it on the end of my fingers, dip it into some water and rub it into the weave all over the surface. It is messy and it looks like hell. when it is dry, sand it all of and you are ready to prime.
Ed S