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NOW instead of using polyester resin (aka Fiberglass resin at homedepot/lowes) use a true epoxy. The kind I use and will be selling soon is from a company out of Corpus Christi called Dewey Supply. You have to Google them and call them up as they don't have a website. Ask for Epobond brand. And its not cheap. But its a much easier 1:1 ratio, it won't catch fire, its nowhere close to as toxic, smells MUCH less, and works better. It also works with caustic materials.
Something you can do is add DRY grout mix after you have mixed together the two epoxy parts. This will allow you to make a soupy/paste-like material that looks like rock but has the properties and hardness of epoxy. This won't work with polyester resin as it can not handle the caustic materials in the grout mix.
Your project sounds like it will be a great one, but you will likely either outright fail or have a much much harder time if you go cheep and use the polyester resin. Epoxy is THE only way to go in this hobby unless you really really know what your doing.
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This is exactly what I wanted to do. I have lots of experience with fiberglass and it's resins, at least from a hobby standpoint, and you're exactly right. I'm not really a fan of polyester resins but I was debating whether it would be easier or not. As far as foam, I was thinking more floral foam as the resin wouldn't eat that but I don't know, I'm still debating. I like your idea of using the epoxy with the grout because I do want some rocky looking areas.
Thanks for the input and keep it coming. It's definitely going to be a slow project as I really don't want to rush it. I have the tanks on the stand with the hood, I should get some pics up later after hurrricane Earl moves out.
