Todo this you will need to read the Fibreglassing DIY article
1. You will need all the items for fibreglassing, listed in the DIY article
2. Also you will need a foam block, one for doing flower arrangements, found at Micheals, or any other craft store
3. A gauge todo the sizing
5. Various sandpaper (36, 50, 80, 120, 240, 55, 1000grits)
6. 2" holesaw
DO ALL FIBREGLASSING OUTSIDE, OR IN A WELL VENTILATED AREA
Keep in mind, fibreglassing is EXTREMELY messy, so anything you use, make sure it isn't something you will need later, or your g/f's stuff, or parents, or good stuff, cause you will destroy it.
There are other ways todo this, but I found this way to work the best, and fastest.
I started out by using a knife, and scraper to design the intended pod out of the foam block. Use the gauge to make sure the design is big enough to fit the gauge when you are done. The foam is EXTREMELY easy to screw up, so take your time.
When you have the design that you want, smooth out the edges, and test fit the foam, checking for visability, and size.
Now it is time to fibreglass, this is where the specific flower arangement foam works best. All styrafoams melt when polyester resin is used, but this foam doesn't. So mix yourself up a batch of resin with hardener. Don't use mat glass just yet, coat the pod with the resin, and let it harden.
Once hard, time to add the glass. But you will need to make the 1 ounce mat glass thinner.....tear it up the middle, into 1/2 ounce mat, this will make it easier to work with on such a small object.
Mix yourself a second batch of resin with hardener. Cut the mat into 2"x2" squares, maybe even 1"x1" squares depending on how tight the pod is. Soak the mat glass with the resin, and put it on the outside of the foam block, doing one piece at a time. Make sure that pieces overlap alittle bit, at least 1/4".
Once you get a full coating on the unit, put a second one on. Let this harden. Before it gets too hard, trim the outside overhanging pieces of glass mat with a knife, or scissors. Or just let it harden, and trim it later.
Now that it is hard, the easy part is coming, take a spoon, and scrap out all the foam from the glass. When it is all out, use rough grit sandpaper to clear out what the spoon didn't.
Mix yourself the last batch of resin with hardener. Cut more pieces of mat, but use 1 ounce, don't tear it up. Now put this inside the unit, this is what is going to make the unit strong. Let this harden. Now you are going to have to trim the unit, a jigsaw, grinder, ect can be used.
Here is where your arm is going to get sore. Use coarse grit sandpaper on the outside to clean up all the rough edges. Mix up the Bondo, and spread a thin amount to the outside. Sand, add more bondo, sand, more bondo, ect, ect untill the unit is smooth and ready for paint.
Once done, cut the hole for the Gauges, I use a 2" hole saw in a drill todo that.
Have fun with it.