A lot time is spent smoothing and rounding edges and the back-and-forth from passenger to driver side to maintain parity. In the future (and after I win the lottery), it would be more advantageous to use a large scale foam cutter, and just hit “print” from our 3D renders and come up with an 90% solution to do minor tweaks on to save time. For now, we’ll trust our fabricator’s Mark 1 eyeball and 20+ year experienced calibrated fingers.
Upon completion of the shaping, there was a wheel and tire final fitment check for turn lock clearance, as well as door hinge limits. Once everything was to our liking, the plug would be sealed for the multi-piece mold. A week or so later, we had our first pieces for test fitting.