Hey guys here is the down under methods lol I use
sketch or draw /design , old method pencil/paper ( my way ) or cad on pc, I
then make a scale model 1:10 or 1:6 cheap way to test design and the 1:6
can be used in a wind tunnel if so desired also changes can be made at this
stage without much cost.
I have used 3 methods each with success I call them freestyle as the mould
/ buck can only be used 1 time usually
balsa/craftwood and 2 pack polyurathane foam liquid ,make wooden cross
sections of design ( craft wood ) ,then fill in with balsa length wise
strips in a latice form work,cut shape and sand to final form, mix and pour
in foam sand to final shape , cover with ( as you call it sheet rock mud
lol) sand smooth ,wax and PVC , then lay up the glass and resin
2nd is very similar but you use polyurathane sheet instead of liquid
3rd I make a tubular metal frame /formwork, fill in/criss cross with thin
aluminium strips to aproximate final shape ,cover with thin plastic sheeting
( i use the type you wrap your lunch in ), then apply a paper mache , cover
with plaster / gyprock cement ( this is what we call sheet rock mud ) sand
to final shape wax and pvc , then lay up glass and resin
warning as has ben stated you will spend a great deal of time during the
process and after filling and sanding ad infinanitum , i finish up the
fiberglass with body repair filler ( bog as we call it ) this is the most
time consuming job and the main drawback to the above methods , but all in
all any type of compound curve can be made and a reasonable end product can
be achieved by almost any one , though it does help if you have a bit of an
artistic flare
Gary
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