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After foam expands and sets it can then be sculpted into desired shape
First rough foam
Once foam expands its shaped to your desire
In shaping process
After foam expands and sets it can then be sculpted into desired shape
Foam expansion tank
The Thin pan mold is installed on the bike and form poured on top
Those Bondo master molds are used to get the first thin pan.When pan proves out the master mold needs to be turned into a stronger fiber glass mold
twistedmax

After foam expands and sets it can then be sculpted into desired shape

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