Making the tank plug
I had some old 1" blue foam left over from my Sabre XLT project so used it for the tank plug blanks
Foam scored with knife and snapped off
12 8" x 8" squares cut
I added a half inch height to the lower shoulder on the template to make use of the space available. I caculated about .2 L increase in volume for that. Then the patterns were traced on the foam blanks
Ready for cutting
The scroll saw was faster than making templates and using a hot wire cutter. Low blade speed was easier to control and worked best. One down and 11 to go!
Cuts all done.
I used 5 min epoxy mixed right on the foam to bond the templates together
Each layer was aligned and squared up then weighted.
All done, ready to sand.
Sanding done on down draft table to control dust
1" dowel and 80 grit in inside curves
Rough sanding done with electric sander
Bar sander smoothed out straight edges
Finished with 180 grit sanding sponge. Ready for rear end shaping.