Most of the photos below, show the details of the rear hatch for the tail extension.
For those who may not know, the hatch is necessary to allow the Honda Insight hatch to get clearance for opening.
This first picture shows the some of the hardware for the hatch opening mechanism. You can see a 1" wood dowel, brass sleeve, and machined aluminum opening pin. The aluminum pin fits snugly inside the brass sleeve, and will eventually rotate to open the hatch.
The aluminum and brass are selected for their rust inhibiting nature, since these components will be subjected to the elements. The wood will be sealed with epoxy and later covered and protected with automotive paint.
Here the wood dowel is being glued in position, and held to a slight offset by the long rod protruding through the housing.
And here's the front side of the assembly after gluing into the foam with epoxy.
Now the backside of the hatch showing the aluminum rotator extending beyond the brass insert.
Here is the start of the latching assembly that will be embedded into the back side of the foam hatch. Notice the 1/4" aluminum rod slid through the wood blocks? Each wood block has a brass sleeve that's previously glued in place with epoxy.
Some of the previously placed fiberglass is cut away to allow carving out a nest for the wood latch assembly.
In addition to the hatch opening shaft, there is a "disk" and opening tool that allow rotation of the hatch from the outside of the car.
The tool is inserted into the end of the opening shaft.
The latch assembly on the far side of the hatch needs a cable guide, and that is shown in the form of a nylon tube, and being glued in place here.
The opening shaft now has a 'stop' to keep the cable taught after final assembly.
Another view of the cable guide being glued in place.
Fresh fiberglass now holds the latching mechanism in place.
While the hatch is setting up, more foam is added to the back of the extension.
And another section at 12.5° of slope on the bottom.
More foam added to the sides.
Two 10" pieces of 'machined' foam to create the curvature that starts over the rear tire.
Ahh, this section is almost done!
You can almost make out the final shape here...
Jim.