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Old 10-02-2012, 06:01 AM   #14 (permalink)
bestclimb
Smeghead
 
Join Date: Oct 2009
Location: South Central AK
Posts: 933

escort - '99 ford escort sport
90 day: 42.38 mpg (US)

scoobaru - '02 Subaru Forester s
90 day: 28.65 mpg (US)
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stack and glue some Blue board insulation with the general shape of what you are after, use a rasp to remove everything that does not look like your new aero shape. Bondo then paint.

Or ribs out of ply some stringers out of some thin wood. Look up the Stewarts process for aircraft covering.
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