MOSAIC HAT PROJECT
Created By Mardi Burns
Part 1 – Using Fiberglass to Make a Mosaic Base
This part of the project looks at how to use fiberglass to make a mosaic base. I've found a hat with a bit of
character at a discount shop and I've covered it in fiberglass it to make it rigid enough to mosaic.
Here are the steps I've taken to fiberglass the hat which can be used on most objects including the
Mosaic Boot by Caroline Freeman (see manufacturers instructions if unsure of what materials can be
fiberglassed):
Step 1 - Materials
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Mosaic Base - in this case a hat
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Polyester resin
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Polyester catalyst
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Fiberglass matt or cloth
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Something to mix the fiberglass
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Paint brush to apply the mixed resin the base
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Drop sheet or newspaper
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Scissors to cut the fiberglass matt (not your best scissors)
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Safety equipment - Safety glasses, gloves, long sleeve shirt
To get you started if your fiberglassing a small object you could purchase a fiberglass repair kit.
Note: The manufacturers safety instructions supersede these instructions and should always be
followed. Please take appropriate safety precautions, i.e. safety goggles, gloves, long sleeved
shirt, work in a well ventilated area and keep out of reach of children.
Step 2 - Cut the fiberglass matt
I cut the fiberglass matt with scissors into a series of squares to surround the hat because the hat is wider
at the bottom than the top which prevented me from wrapping the matting around. Then I cut a series of
shapes to cover the rest of the hat.
Step 3 - Applying the mixed resin
Mixed resin is the Polyester resin + Polyester Catalyst (or hardener)
To apply the mixed resin you brush the resin onto the surface and then place the matting on top pressing
it in. Apply more mixed resin on top of the matting until it becomes clear.
I found working in small sections at a time the easiest as the hat is oddly shaped. The brim was the
hardest part as I had to fiberglass over the edge of the brim. To do this I cut the matt into strips of 34 cm's wide and wrapped them over the brim, holding down the matting while it takes hold.
Don't do what I did and apply the resin to the top of the hat and under the brim at the same time. You will
have to hold the hat until the resin has cured sufficiently to put it down.
If you have to apply additional layers of fiberglass you may need to sand in between layers to get
satisfactory adhesion.
Step 4 - The clean up
Cut off any strands of fiberglass matting. If you need to sand the fiberglass to remove any bumps etc
follow the manufacturer's instructions as it can cause skin irritations.
Additional notes on Fiberglassing
In the last section of the fiberglassing I used a fiberglass cloth rather than the matting. It was a lot easier
to use and gave a much nice and finer finish. It's apparently more expensive (according to my husband)
but I would absolutely use it again. I found that the matting tended to 'fiber up' requiring more resin to
even out the surface. If using the cloth keep it straight and even, I had some areas where it doubled over
and had to cut them out and apply more resin.
Fiberglass using the cloth
Fiberglass using the matt
Part 2 – Mosaicing the Hat
Supply List:
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Red stained glass chips
Assorted white Millefiori
Assorted red Millefiori
Micro red / Pink Mix Ceramic Tiles
1 cm mirror tiles
Daisy glass gems
Irregular glass gems (for white detail)
Liquid Nails - clear
White grout + Brick Red grout colourant
Wheeled glass nippers
Latex gloves
Safety glasses
Disposable or plastic bowl, sponge
Tweezers for placing the tiny tiles
* 1 packet of stained glass chips covers an area of 14cm’s square (approx)
Note: these supplies do not include those needed to fiberglass the hat
Directions:
1. Tile placement and gluing time
I used clear Liquid Nails to adhere the tiles & tesserae to the hat. Liquid Nails is quite a tacky
glue so I used a cheap paint brush to apply it. Don’t use a good paint brush as you will be
throwing it out at the end of the project.
You will need to do some clean up work on the tiles before grouting to ensure a good finish. Its
drying time (a few hours) gives you plenty of time to manipulate your tiles to achieve the design
your after.
Draw a line around circumference of hat for decorative band
Millefiori is a great way of adding detail and breaking up the stained glass. Red Millefiori is
used on the top section of the hat and white Millefiori on the section below the band
The daisies and irregular gems create a decorative focal point and are added to both sides
of the hat
The band is made using Micro red / pink mix ceramic tiles and 1 cm square mirror tiles
The tiling was continued under the hat to the end of the brim.
When the surface of the hat is complete, allow the adhesive to cure according to the
manufacturers instructions before applying the grout.
2. Grouting Time
White grout mixed with Red Brick Grout colourant. I made up a larger quantity of grout that
required to ensure I wouldn’t run out and mixed 1 container of the colourant.
Once grouted allow 24 hours for the mosaic piece to dry thoroughly. Notice that the grout
was also used to cover the inside of the mirror as it is too narrow to tile. Alternatively, you
could paint the edges with acrylic paint. Whatever finish you choose ensure that it is neat,
this is important for the inside of the mirror as it will be reflected.
Tips:
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Safety first – use protective eye wear when nipping glass
Never dispose grout down the drain
Mix grout in a disposable container for easy clean up
Mix enough grout to complete the entire project
All of our products are not toys and must be kept away from young children. Tiny tiles are
not frost resistant or food safe.
Beginners Guide to Grouting
Mix the grout according to the manufacturer's instructions. It should be the consistency of thick
oatmeal before it is applied. If you accidentally add to much water simply let it sit for a few
minutes and it will thicken up, or you can add more grout. Stir until smooth. Be sure to mix
enough grout to cover the mirror to ensure colour consistency.
We suggest that you use gloves when working with grout. While it is non-toxic it can dry out
your hands. You will go through a few pairs whilst grouting.
When applying the grout press it down in the spaces between your pieces and sculpt it on your
edges to make a nice smooth edge. Generously cover your entire piece.
Once you have covered your entire piece and filled in all of the spaces, wipe off as much of the
excess grout as you can with your gloves or hands. After you do this allow the piece to sit for
20-30 minutes or until the grout becomes hazy. Then take a slightly damp sponge or cloth and
wipe off the haze. Buff and shine the tiles with a dry cloth. Remove as much grout as you can
from the tile surface as it will be much harder to remove later. Do not use paper towels as they
flake off and stick in your grout. I find baby wipes come in very handy during the clean up.
Allow the grout to dry. A grout sealer can be applied once the grout is dry to keep the grout clear
and protected.
Legal Disclaimer: No warranty is implied by these instructions. Use at your own risk. Specialty Art Glass
and its proprietors are not responsible for the results of any actions taken on the basis of this information,
nor for any omission in the advice. Please wear appropriate safety equipment when cutting mosaic
materials and using grouts and adhesives. Always follow manufacturers instructions which take
precedence over instructions contained within this project.
Keep out of reach of children.