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Old 09-26-2019, 03:42 PM
Chris Nicastro
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Join Date: Oct 2005
Location: Coeur d'Alene, ID
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There are ways to do it. In order to keep it light you can cut foam and shape it to look like the offset inner panel. You can use balsa and do the same. Combination of balsa and body filler like Evercoat would be my choice. You can seal the wood with thin CA and work it like a hard foam. If you use foam you have to worry about CA or body filler melting it. With balsa you can shape, seal it, hit it with a building primer and paint it. Look at Upol urethane automotive primer, it’s thick, dries fast and is compatible with most paints.
You could make master models and mold them in silicone then cast them in urethane, light weight and durable, cast in color.
You could make masters and vacuum form with styrene with a shop vac set up...

Just depends on on your preference really
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