Remodelling a fibreglass body

[RazMan]

I need to remodel an existing fibre glass wing, raising a body line by about 20mm and smoothing out some sharp corners in the process. I could just start dolloping on loads of filler and carving out the shape but I am sure there must be a better way - it would weigh a ton!

Can I pad out the wing with a plywood former (attached with rivets) to increase stiffness, then apply filler over the top?

[RazMan]

My main worry is that the 'prosthetic' (sp) part will be very heavy - not to mention expensive on filler. At the thickest point it will be about 100mm and roughly a metre long!!

I was thinking to pad it out first with wood or another material (screwed to the existing bodywork) to get the rough shape and finish it off with a layer of matting, and finally filler.

[RazMan]

Leaving a hollow void? Won't this create problems?
Also, what is the easiest way to make a mould? I would need to make two 'handed' ones for left and right wings.

[RazMan]

Thanks Fatboy, when the time comes I will give it a try

[RazMan]

The big boys use clay don't they? How about carving the shape 'in situ' using clay applied directly to the bodywork, then covering with cling film, release agent - then CSM to create a female mould. Then more release agent and apply CSM to make the prosthetic .... then attach and fill.

Does that sound like a plan?

[RazMan]

Fatboy said:

No idea where you get clay from though, can't be hard to locate.

My missus is a potter and won't miss a 25kg bag or two! I'll just go into stealth mode and see what I can find