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Originally Posted by gijoe985
Well... This project was not abandoned. Just moving slow.
how does this approach sound: shape the foam as close as possible, fill with what, plaster? Car filler? Once filled and smooth I could cover with fiberglass or I could make a female mold and then make a super nice mold... If I make a fiberglass mold, I assume I'll need to reinforce the inside. And then comes the fun of figuring out how to attach it. I was waiting to cross that bridge when I got there.
Thoughts? I'd like it to look nice. I'd also like to figure out a way to have a hatch that opens still too...
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Since you're working in foam,check out 'Honda Insight Tail Extension Project',by 3-Wheeler.
He used micro-baloons (CABOSIL,fumed silica) and epoxy as a ultra light weight filler.You might want one coat of resin on the foam first.WEST SYSTEM sells this.I get mine at a local marina which does Chris Craft restorations.With a single layer of glass it would be strong enough to remain on the car.Or you could make a female mold from it and layup your finished part.