I have been thinking about trying to make body parts that arent available in the market. Decided the best way to do this is the design them and then cast molds from fiberglass, in order to recreate the parts in FRP. I want to design some front fenders that are wide enough to accept the 9 inch wide wheels without massive camber. These already exist. I know. But what I would also like to see is a fender that will accept this width of wheel and tire, but allow the suspension to be lowered more and not suffer fender damage. Therefor, I envision a high fender lip with some width to it.
I have been playing with the shape. Originally thinking I could template the design, transfer it to sheet metal, cut an old fender and use the mounting points from the donor fender, and attach the sheet metal fender design to the mounting flanges. Then of course mold it, and create a pretty, light FRP product. This would effectively remove some of the angles that the stock fender shape has. I also thought, that if I am doing that, I might as well do the front bumper too. This has proven not easy to do with the same fashion as the sheet metal fender. So I got thinking about using foam boards the build up and then shape the front, and then cast that with fiberglass mold.
I am after something more modern and aggressive looking. I spent a lot of time looking at cars from JGTC and their aero designs. Now I am wondering how do I cast fiberglass over a big ass foam bumper shape? The foam wont survive the reaction without a barrier will it?
These are just my thoughts. Maybe it will spark some discussion.