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do some searches on youtube etc theres prolly a few hundred vids that help more then text. in curves and high stress areas pull some fiberglass strands and lay them in for strength(in corners and along edges etc) Wax the mold spray gellcoat fiberglass it up. clean it up and check for imperfections sand etc till your happy. and glass them in to critical areas to prevent the mold from flexing.Īfter all is cured and the mold is pulled off the piece. use some pieces of scrap wood or the reinforced cardboard supports in some boxes. and start to cover with fiberglass make it a U shape basicly cover the flange you made for bumper,front of piece and the bottom. some use cooking spray some cover in tin foil and some will spray a nice layer of mold release. Theres many different ways to go from here. the ply should be a fairly rigid form and you should have a nice imprint of the bottom of the bumper cover from when you filled the gaps. when you have the rough dimensions you want you can start using clay or bondo and blend the layers of plywood to a shape you like fill all gaps between the ply and bumper.Īfter your happy with the shape and design remove it. if you want it to extend out cut the ply larger in that direction. if you want it to be lower add another layer of plywood. (inside and outside cut the shape out and fit it to your bumper(clamps,jacks etc) (can screw in if you wish but it adds holes)ĭecide on your shape. trace the bottom lip of your bumper onto a piece of plywood. decide on a shape you want and how far it will drop your bumper height and extend past your bumper.

You can start by covering your bumper in painters tape. be it from wood,clay,fiberglass,bondo,expandable foam. You would have to make a mock up of said part to make a mold of it. making a mold and making parts from it is hard but its not the hard part of this. If its your first time ide advise against it.

Ide say making a lip from scratch is an 8.