I'm going to cover the plane in fiberglass clothe. I understand I need to fill and sand the bare wood before I start covering. My question is what's the best filler to use. I have some SIG sanding sealer which is a butyrate based filler. Is this compatible with Fiberglass? Or should I look at something else, microballoons perhaps?

Another question is, I'd like to use as much water based products as is practicle. Latex (or is it Acrylic?) paint from War Colors being the final surface product I plan on using. Since it's been a long time since I did this is there any new processes on the market that's safer as far as fumes go. The butyrate stuff mentioned above would be better avoided as far as I'm concerned.

Do you plan on flying this plane?

i wouldnt worry too much about sanding and prepping as if you were gonna cover it in monokot/ultracote... since you will be doing a ton of sanding to the fiberglass

I just glass onto bare wood. If you are concerned about the fumes or are allergic to epoxy then use the stuff called G4; the pool guys sell it for sealing tiles.

Do be aware that glassing has several pitfalls and if badly done adds a ton of weight plus you may finish up with fish eyes, sags and areas that remain forever tacky!

zap finishing resin is the best ive ever used....beats the old K&B epoxy my dad used to use