Here's the challenge.
We wanted to keep the bodywork as authentic as possible and still be able to drive on the street. We had to raise the front end about two inches to keep the front valance off the pavement. This gave the car a four wheel drive attitude that we didn't like. The solution was to section the valance a couple inches and then add a rubber chin spoiler.
The first step was to add a flange on the bottom of the valance that the rubber spoiler will mount to. This will also keep the bottom of the valance flat when I make my cuts to section it.
This is where some careful planning pays off. I can make my horizontal cuts in the middle of the valance on the sides and thru the square opening without any ill effect on the final outcome but if I cut thru the center of the round openings I'll end up with ovals when I'm done. I'll have to re contour the surface below the round opening but I thinks it will be easier than messing with the surface deeper into the opening.
A variety of cutting tools, a lot of fiberglass dust and the sectioning is complete. The cut lines are almost perfectly parallel making re'glassing the two back together much easier.
metal tabs are used where surface alignment is critical.
Both sides of the cut are beveled and taped together on the back side.
The beveled cuts are filled and once the 'glass has cured it's ground flush with the original surface. 'glass, grind, repeat untill the two sections are back together as one. This view also reveals how the taper of the wheel openings are misaligned.
Some creative cutting and 'glassing brings the tapered surfaces back into alignment.
We've been having some unusually hot days here which make working in 'glass especially difficult. You have to back way off on the hardner and then work twice as fast 'cause the resin will kick fast. The heat also opens your pores and allows the 'glass to get in real deep. This is what makes you itch. Repeated showers with the garden hose helps but it makes your neighbors wonder what you're up to.
Updates when they become available.