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Old 06-30-2012, 02:26 PM   #9 (permalink)
aerohead
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bicycle rack?

If the tail is going to swing away with the hatch you'll need to know if the geometry of the existing hatch hinges will cause interference and binding as the tail swings from closed to open position.The top of the tail may want to collide with the roof when raised.
If you had a sturdy hatch-mounted bicycle rack the tail's superstructure could be attached to that and then 'skinning' only the perimeter of the tail,where it must interface with the Focus' body,you could move the tail through it's entire range of motion to be sure that everything will clear.
If you like what you see,then you're good to go with a permanent shell.
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Cardboard and masking tape can be used to construct a mockup for actual on-road testing (tufts and mpg).
If you're pleased,graduate to coroplast and aluminum.
Fiberglass over foam is also a great way to construct.
You can also do fiberglass wet layups over cardboard directly on the car ( with a suitable 'release area prepared) and later soak the cardboard out from 'underneath' the glass layup after completed,leaving only the glass shell.
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