Here are the new wheels. They're the latest 6UL's from 949 racing. 15x8 in the front with a 205/50/15 and 15x9 in the rear with a 225/45/15 BFG Rival S.
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I made some fender plugs out of a bunch of layers of insulation foam, shaped them on the bandsaw and did a little finish sanding. Wrapping them in packing tape worked wonderfully for allowing the fiberglass to easily release afterwards. For fiberglass materials I'm using west systems epoxy and 1708 biaxial fabric. I was originally thinking I would need 4-5 layers of fiberglass but I removed them from the plug after 3 layers and they seemed more than strong enough. They come in at 2.5-3 lbs per fender.
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I simply taped down some pink foam to form the general shape of the hood. For a while I toyed with the idea of more elaborate body work and fenders but I thought I better make it as simple as possible to increase the chance of me actually finishing it. The idea was to glass over the foam while it was on the car so it would hold it's curved shape after I removed it. I put 3 layers on the top and when I removed it from the car it held it's shape pretty well.
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The next step was to mark out where I wanted to remove or clearance the foam. After removing some of the foam I found the hood still sat on the car properly but when positioned upside down it was easy to alter the shape depending on where I supported the hood from. To make sure it maintained the correct shape I whipped up a foam cradle for it to sit in. I added a bit of reinforcement in the areas I was going to cut holes and then put 2 layers of glass on the bottom.
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In hindsight I should have maybe done 2 layers on the top and only 1 on the bottom. The finished hood came out to 24.5 lbs which was definitely more than I expected but on the up side it's incredibly strong. Overall I'm pretty pleased with the results as this is really my first fiberglass project.
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