I wanted to build a custom lip for my car and there wasn’t anything on the market that I liked. Inspired by the Japanese “bozozuku" style cars I wanted something a little more outlandish but still tasteful. I wanted something that stood out but still derivable.
I started off with a metal and wood pattern and used expanding foam to create shape.
I shaved the foam with a saw blade and sanded it to shape with 80 grit sandpaper.
I kinda cheated here. I knew there would be a lot of surfacing ahead of me so I used painters tape as a mold release surface. Ready to lay the first layer of fiberglass.
You can see the fiberglass is laid over and the surfacing begins. I used a sandable gel coat and lots of primer. You can see the black guide coat sprayed on to show the low spots after sanding. This was the last volley of sanding and it will be ready for paint.
Final product. Painted and clear coated in the garage paint booth and polished to a mirror finish!