> Bigger quantities get hot and react quick

Yes, some patience is needed. Because the reaction is exothermic,
pours with a low volume : surface area ratio can get too hot inside
if the catalyst level isn't reduced accordingly. If encapsulating, over-
heating can lead to cracking or silvering as the cooling resin shrinks
away from the encapsulated object. The heat can also be enough
to vapourise any moisture in the object, which doesn't look good,
so dry everything and keep the heat down

You can encapsulate in layers, by pouring on to the previous layer
just as it starts to gel, and that layer's surface is still liquidy. Takes
practice and good timing. For example, for an object to appear
suspended, you can either pour a layer to rest the object on, if the
softy-gelled resin will take its weight, or hang the object from a
thread, pour enough to support it, remove the thread when the first
layer gels, and cover with the second layer. Note that softly-gelled
resin tears, as it's only partly polymerised, so care is needed to not
move the object too much

> Small quantities are hard to do because of the tiny amount of
> hardner required

I have a friendly doctor who is able to let me have diabetic syringes.
You can use an eye-dropper, where 25 drops is ~ 1 ml

> Get some rubber gloves and craft sticks

And acetone. It's about the only cheap efficient solvent for a quick
clean up

> I like to mix on an old magazine

A breeze is not a bad idea. And not in the house. Styrene fumes
linger. You might not notice, but visitors will feel compelled to
comment

> Hair spray and Green Slime (auto tire patch) are good mold release=20
> materials

And some waxy furniture polishes, not necessarily carnauba. It's
possible to cast on glass if well-prepared, but watch for shrinkage
defects in the surface

For shaping/polishing, work down the grits. A 60-grit belt makes
quick work of polyester but will gum up. At the other end of the
scale, polish with finest wet-and-dry emery and/or Brasso/Silvo

Polyester turns very well on a metal or wood lathe but can shatter
if you try to cut or drill it too enthusiastically

Joe
--=20
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