Quote:
Originally Posted by theycallmeebryan
I am mostly interested in how he made the fairings for the bike. He made a youtube video of the whole build process. I am planning on using a similiar process to construct aerodynamic fairings for my ninja.
Does anyone know what kind of foam is best to use as a plug? Particularly one thats easy to cut, sand, and shape. I'd imagine i'd buy it in flat 2-4" thick sheets and glue them together.
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Floral foam works good for small stuff, but I don't think it comes in bigger sheets, and making big blocks could get expensive quickly.
If you can start a very rough shape with cardboard, then wet paper over that, then spray foam over the paper once it dries, you get a very cheap, strong positive mold to start with.
Extruded foam insulation works great, but you can't cut it w/ a hot wire knife, because of the fumes it releases. You'll need sharp knives, a sharp rasp, and several grades of sand paper to work with it. You can get it in VERY thick sections, like up to 4".
There are other types of foam you can use, also.
