Initial concept drawn out on paper and cut to fit in area on the side of the bike.  Radius of curve to match the radius of the wheel.

Purchased 16”X 24” sheets of 4” thick polyurethane 2 lb “carving foam”  Here is the link: http://www.amistorefront.com/SearchResult.aspx?CategoryID=26 Great stuff and great folks.

Using 3M spray adhesive (get it at Home Depot), glued sections together to create the shape based on the template.  I used a bare hack-saw blade (with gloves) to carve the foam.  This is the rudimentary mold for the Fiberglass.  

I first covered the foam “plug” with Aluminum Foil so I could release the plug from the fiberglass.

Laid the plug with fiberglass, Released from the urethane mold and shaped with fiber reinforced filler, lightweight bondo and finishing with Dynatron #592 Polyester glaze.  Some folks prefer the Evercoat stuff for the finishing glaze.

Using Primer for guide coat, sanding, then repeat, ad infinitum…

Hint:  Don’t skimp on the hardener in order to allow you more time to skim.  This will produce a chewy mess and will gum-up your sand paper with one stroke.  Use the recommended amount of hardener.  

Fabricated some mounting brackets to mount to top and bottom radiator mounts

Test fit

Test fit for interference points to be rectified.

Use a High Build primer to create a smooth surface block sand.

I painted the plug the  Illusion Red stock color and rode around with it for a while.  

I later sanded the paint off and applied another coat of grey high build primer in preparation for the creation of the mold. To continue on to the mold and final part page, click here