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Originally Posted by dr.freemanstein
I have however, thought about the "plug" problem. I thought maybe, seperate panels could be manufactured from papier mache or something.
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I haven't used papier mache since I was a kid - would it be strong enough? When making a mould out of glassfibre it has to be built up to three times the desired thickness of the final panels, and will be heaviest during the casting process as the resin & gelcoat are still wet. I was thinking of perhaps filler on a wooden base, or something?
It occurred to me after posting last night that the really hard part could be mounting the finished panels on the chassis, so that they look good, line up with adjacent panels and withstand 100mph of air buffetting.