Here is the process I was thinking; start off with a piece of foam and you pretty much carve out the shape you want and fiberglass over it to get the form and then cut around the sides to get the nice squared off shape and drill the holes for the tabs, maybe using two layers of fiberglass placing the second after the first has dried for a nice strong material. Before using the fiberglass I would try coating the foam with parafin wax so the mold might be reusable.
Has anyone done this? How hard is it to do? Would the wax thing work? Any tricks or tips before I try it? (I am not trying to reproduce an existing fairing I am trying to make an entirely new design for the tail.)
Has anyone done this? How hard is it to do? Would the wax thing work? Any tricks or tips before I try it? (I am not trying to reproduce an existing fairing I am trying to make an entirely new design for the tail.)