UPDATE: Installed pics on page 4
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Just starting this project... so this is a work in progress journal.

Last time i got the whole rear diffuser sculpted and messed it up when I started glassing...
This time I'm starting with the side splitters...
... and am not going to blow it with an "undesirable chemical reaction"

Here's a couple of pics of the blue foam blanks:




I'm thinking Flat black...

 

Looks like we're working on very similar projects. FYI, if resin melts your plug, you can simply spray your plug with a couple layers of automotive primer.

Good luck

 

^^^ Cool -
Good luck with your project


I'm going with epoxy...
polyester resin will melt extruded polystyrene foam (XPS)... but epoxy won't...
--- see "undesirable chemical reaction" above.

 

Looking good. Keep it up.

 

Good luck!

 

couple more pics -
DOW square edge foam -- ready for glass






end caps need some shaping still... working on making them thicker.

 

Wow, impressive. Your molds look good. Interested in seeing how it works out.

 

Very nice! Can't wait for the finished product.

 

 

I was thinking of doing this exact project but I was looking to do them with aluminum or some other manageable material that doesn't require a mold. Looks good though.