|Scrap Ply to use for the plug|
|Nailed into place|
|Expanding foam to fill the voids|
|Should have used 2 part expanding foam as there were so many air pockets|
Then I glassed a female mould with 2 layers of woven cloth and a layer of chop strand. Because the foam wasn't perfect I had to spend a bit of time sanding and filling the holes left by the foam.
Next I created the final male mould, this time I used a Vinylester Resin for increased flexibility and strength compared to the Polyester.
|Vinylester Resin with woven mat|
|Final result after sanding. Ready for primer and paint|
It came up really well after a trim and a light sand and fits perfectly to the rear tyre and is also super lightweight. Now to fabricate the mounting hardware.