mold making ideas

Hey Everyone, I am trying to make some fiberglass inner fender wells for my car.  My car is bagged and I will be making some alterations to the inner fenders for clearance reasons.  I would like to recreate an inner fender cover to match my alterations.  I was thinking of using the stock inner fender liner as a base, but not sure how I would go about adding the new clearanced areas.

 

I can't flip the car over and lay glass in there, so that idea is out.  LOL.  I have thought of using expandable foam but not sure how to go about keeping it from drooping down.

 

Any Ideas?

 

Thanks

 

Shawn

Thanks guys for your input.

 

slinkycyrax, the inner fender liners on my car are plastic and bolt up to the front fascia.  I need to keep something in there to stop the front fascia from flapping around at speed.  I still have a inner fender, so to speak, but it has a huge lip pointing directly down and spot welded.  I wanted to cut that lip out, reweld it along the bottom edge and then build a liner to go back inside the wheel well opening with added area where I cut out the lip.

 

tubbs04, this is on a unibody car.  There is not access to go from the top if I were to drop the car down and then glass ontop of the wheel and tire.  Wish it was gonna be that easy, and it did cross my mind.  LOL.

 

So far, the best idea I can come up with as a viable solution, is to make a wood frame that goes up and over the tire, then place a garbage back on top of it and fill it with expanding foam.  That should allow me easy clean up, and also give the expanding foam more room to go sideways as to not put too much pressure on the fender.

 

After staring at the factory fender liner, I think I am gonna just reglass the changed part at the very top right onto the factory liner.  There are alot of holes and tabs that would need to be fabbed in order to attach it like it was stock again.  So I think I will just cut out the section that needs to be raised and add the glass to that with the mold I created.

 

Does that sound like a PITA, or is that really my only option at this point?

 

Thanks for your input guys.

 

Shawn