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I'd prefer a more rounded top-side transition if possible. Sharp angles can trip smooth airflow into unwanted vortices, according to people smarter about aero than myself.
Fiberglass... I did some searching on how people make custom body kit add-ons, and it's a pretty complicated process:
- Build the prototype on the car out of whatever combo of materials you want (wood, metal, high density foam)
- make a mold by coating the prototype with fiberglass
- use the mold to make your good copy...
Those are the basics, as far as I can tell, anyway.
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