Anyone built their own bodywork without a mould?

[WorldClassAccident]

Thanks Paul, helpful.

My thinking with the oversize/undersize issue is that If I make the former to match exactly witht he door panels and then add CF the panels will be Xmm to big, as you say, but if I then stick the same CF cloth to the doors then they will also grow by Xmm so be the right size again. Make sense?

This guy makes it look easy : https://www.youtube.com/watch?v=0Yaggj16S08&t=1195s

[Lucky@LeMans]

This works on a bigger scale too, boat hulls being made here.........
https://www.youtube.com/watch?v=NqzjMc_xBjg

[Mister Towed]

Originally Posted by WorldClassAccident

Thanks Paul, helpful.

...If I make the former to match exactly witht he door panels and then add CF the panels will be Xmm to big, as you say, but if I then stick the same CF cloth to the doors then they will also grow by Xmm so be the right size again. Make sense?

You might want to rethink that as I would suggest that if you set the panel gaps on your former exactly as you want them then oversize each panel by adding your CF cloth and resin, the panel gap won't remain the same but will reduce as the increased dimension on adjoining panels will move towards each other, not both in the same direction.

Apart from the technicalities regarding the plug, I can see this working now I've watched the video of the chap making the small item without vacuum bagging it. The main advantage I can see over using fibreglass is that the surface finish looks like it will be much smoother than when you use fibreglass, so will need less prep for paint. That all depends on how good your plug is though.