Starting the plugs for the bumperettes and front spoiler.

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For making plugs with anything soft like balsa, drywall mud is your friend. Sands like balsa so you don't over-sand.
Might have been able to do this whole thing on the printer but likely just as quick and accurate doing it by hand, some printed parts and some hand formed. Fairly square and symmetrical but as you can image the center line of the nose isn't perfectly centered so playing the compromise game to get it better.
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First pass at primer and blocking to confirm shape works. Will crisp up the lines and flatness, then a mold.
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Beginning shaping the sides. Guys in the shop are a ton of help, with helpful eyes! Super thankful. Lots more before a mold.
I'm pretty sure this is ride height, at least for the street. 4 1/8" in the front, what do you think.

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4 1/2" is low, but should be streetable. Great work John.

My rule of thumb is 5” for no road contact. You will have to be careful with driveway approaches etc in my experience.

Very cool, John!

That's awesome to have a friend who will let you use their shop to work on your car.

Thanks guys, appreciate the feedback! I raised it up to 4 7/8" of ground clearance.

Laid down a handful of layers of drywall mud to get the shape.

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More mudding and I built an inner structure inside the spoiler so it perfectly holds it shape when removed from the car. If it moves at all, the mold will be junk.
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Took a step back and fixed a bad angle where the fenders meet the spoiler, well worth the effort... much smoother line now.
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Final sweep with body filler and drywall mud. I like drywall mud for making plugs in some cases; it's cheap, sands super easy, allows easy shaping of complex curves and for sure it's the only way to go when using balsa as they sand very similarly.
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A handful of heavy layers of filler primer rolled on, final blocking is next. And then onto making the mold.
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You're the man!! :king:

I am looking forward to seeing more progress pictures


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Thank you gents!
Final test fit of the spoiler and bumperette plugs before mold makin'....
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First sections with gelcoat and the first layer of glass. Long way to go, best to do only a layer or two, maybe three at one time so curing is more stable. Just time, right??!!
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Bad ass


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