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I bought my new tray, after verifying the diameter with my tape measurer, and it fit just inside the lip of my rim. In fact, it actually sat there, held in place by the lip, so I wonder if I could use that. I thought about how screen windows are created, using that spline to attach the screen to the frame, but I just do not think that it would work for my application.
In order to make a plug:
1. Clean my hubcap.
2. Attach plastic or something between the spokes, without any gaps.
3. Coat it with wax (several layers, buffing in between?)
4. Coat it with release agent (several layers?)
5. Cut the fiberglass fabric to fit, apply resin, and roll out air.
6. Repeat with multiple layers.
7. Flip it over, wax and apply release agent to the other side.
8. Cut more fiberglass to fit the front, apply resin, and roll out air.
That would make normal hubcaps, but in order to make smooth ones I am thinking that I need to do the above, but only for the center and the spokes. If I center that on my pizza tray, I can bring in the rim, but either I would need to leave the center open or make openings or tubes to reach the lugnuts. I could potentially cover any of those, but it just seems more and more complicated.
From what I have seen in the videos, 90° angles in fiberglass are problematic, but I think that is mostly due to the tendency of air to trap.
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