Originally Posted by TJ Bear

Im a composite technician and own my own boat building business and to do it right would cost a mint. First you would have to design the part in CAD then have it CNC cut in foam, this woulkd then need to be sprayed with a high build compond and sanded and buffed to a automotive grad 1 finish. This is called the plug, of this you would need to build a mould using expensive tooling gel and VE resin/chopped strand mat and brace it to keep it stiff. Now your ready to make a part, you will have to seal and wax the mould, design a laminate schedule that meets the engineering requirements for stiffness, weight etc then laminate either by hand, vacuum infusion, wet prepreg and bag etc. When the part came out of the mould it would need to be detailed and maybe 2-pac sprayed and buffed then fitted out for any windows, doors latches lights etc. To do it professionaly it would cost 20 times more then to buy it retail of a vendor. There is a reason these parts are expensive there is huge tooling and setup costs to get it right. Just my 2 cents for what its worth.

Originally Posted by Smopho

That's a bunch of overkill for a one off item. IF you were making production parts, then I could see doing it that way. You don't need a mold for bonded panels with a stitch and glue method of construction and you sure don't need CNC equipment.

Originally Posted by reddragon

Why not spend the time needed to build it at work and get the dollars to buy the real one? Much better than ending up wasting time and money on something like this.

Originally Posted by gregkuiper

If I were in your shoes I would just use the wood as a base to form the glass and then take it out. You can do this by placing aluminum foil over the wood and then glassing on top of it. I have done some really nice glass work on prior vehicles using this method.

Originally Posted by So_Cal_Tay_12

How do you heat the glass to bend it?

Originally Posted by nikbass

I like this guy he will not quit. Kudos again Tay