Making a one-off custom tank
Any suggestions on the products and process to make a one off, lost-mold, custom tank?
I'm assuming you could carve and sand the tank shape out of foam, allowing a little clearance and some gentle radiused corners. Then split the foam block and hollow out most of it. Reattach the pcs then cover with Kevlar twill weave cloth and epoxy. Once cured, open a hole for the main fuel fitting and melt away the foam using acetone, spending time to really get the foam residue out.
I've worked with carbon fibre cloth and fiberglass, but never kevlar.
Any input or suggestions? Or is this not really a wise do-it-yourself project, and smarter to just send the foam blank to Gary at JetTech to make the tank?