Fiberglass Piller Pod?

I am making a Triple Gauge piller pod for my 00+ impala.(They currently do not make one for my year yet). So im basically looking for advice to see if im doing this right, This is by far not my first fiberglass project. I have herd many things about fiberglass and plastic not sticking and I want to make this a one time deal. This is essentially what I did.

1st: I took the stock piller out of the car and sanded it all down with a low grit sand paper.( To rough it up)

2nd: I took the donor piller pod that  I had left over from my last car(cavalier), Measured it up and marked where I wanted it to go. I cut the pod to size. and screwed it onto the piller so it didnt move around.

3rd: I used some body filler around the edges to make it smooth and make it look like it was supposed to be there. I sanded the crap out of the body filler so it was even with the pod.

4th: I layed some Fiberglass Cloth all around the edges of the piller pod. The fiberglass cloth is layed really smooth. No air bubbles. I just dont want it to come off of the piller. I want a good adhesion.

Now I didnt sand the fiberglass yet, I also didnt rap the fiberglass around the piece onto the otherside. Im not sure if I should have. Here is some pics. any help would be great.

First, heres a bit of useless information.  I used to have that same design of bedspread...um, nevermind.

Heres how Ive been fabricating my components.  https://glassmanscustomforum.com/v-web/gallery/album1996?page=1  I dont start the same way this individual did in this case, but the concept is top notch.  I start by covering the complete pillar, therefore creating a replacement pillar completely fabricated of FG mat, note his first picture is only a part of a pillar.  Separate the pillar and your FG pillar, cut off the excess, deburr the edges, and TEST-FIT the component.  You can place your prefab pods anyway you like as this guy and I do with our PVC (pics 2-6).  I only cover what I need with the thin stretchy polyester cloths, attaching it with 2 part glues covering the pods as the pics show.  Also glue the faces of the PVC on the gauge side.  Saturate with resin, let cure.  Scuff all FG surfaces with rough grit (from 36 to 80 grit) sandpaper.  Use body filler in areas that require build up/contour.  Use a filler grater to remove excess and shape the areas as needed.  Scuff / smooth the area with 100-300 grit.  Use glaze putty (Rage Gold/ or whatever) to fill the small imperfections and such.  Prep-prime-prep again-paint/vinyl/carpet/upholster the new pillar .  Install gauges, wire them, and install.

Thats what I was gettin at. BUT, you explained it much better. there is no reason to keep the FG attached to the factory piiiar.

Yeah well I want it to clip in like stock so I want to use to stock piller and the gauge pod that I have made. I just need to attach them together. I dont want it to look custom. I am a little confused because both of you want me to make a mold and i just want to mold it together.

Sure, whatever works.  Im glad you brought the size of 1/32 up.  I was looking at  my drill bin and saw the 1/32 bit and realized I should have recommended a larger size!  Depending on the location and the nature of the finished product, I dont like to deal with the bumps that the screw heads create.  This method alleviates that issue, using larger holes.  

.....im recalling....the story I wrote earlier regarding building a mock up/replica of the factory panel...which avoids this whole problem.....

I kno torquehead tried to tell me to just make a replacment piller instead of doing it the way im doing, But I really want the factory feel and I want it to be able to clip into place like stock so Im Hell bent on doing it my way.

Currently I have it fiberglassed but its not wrapped around the edges so im going to wrap the piece in polyester cloth and fiberglass it again.

Its cool, and still a good idea, youll have the factory mounting method as well....it should remain a perfect fit.  Beforehand, I didnt know it was your personal requirement to use the factory peice.  Your project is all about you, its supposed to be your way, youll appreciate it more. 

I know plenty people dont think my was is easier, and its often that its not easier, I sometimes like it that way!  This also ensures that I get the hard-to-do jobs that even the local fabrication shops dont want to touch.  Its just the extent of my projects being intricate keeps my portfolio revolving.  So...im just trying to help.

Oh, careful when wrapping the plastic panel in fleece tightly.  Sometimes the fleece pulls the part out of its intended alignment.  When its cured in that warped shape, it could crack when its flexed back into original shape during mounting....or a bit after. 

Got more pix yet?

Well Hear is a little Preview of how it started up till today...

I was originally going to make the pods out of Fiberglass then i decided differently

Old cavalier Piller pod

I had to cut the cavalier piller pod and heat it with a heat gun and shape the pods to the impala piller. Filled the edges with body filler then fiberglassed over it

Sanded the crap out of it, But as you all know I forgot to wrap the edges

Im going to be finish sanding tomorrow then wrapping the whole thing in some stretchy poly clothe . Ill post pics tomorrow of it wrapped 

hey Torquehead what size pvc pipe did u use for the gauges?

I use whatever size is closest to the diameter of the body of the gauge, but the PVC must be larger.  I first measure the length of the PVD that is required and leave a bit extra for mounting error....the ultimate length is determined by test-fitting the PVC.  Then if the PVC is too large in diameter I just simply cut it length-wise on one side the full length of the PVC pipe, then cut some width out of it.  I then use some hose clamps to close the gap.  While the PVC is clamped, I use a heat gun to relax the PVC.  Glue the PVC gap together.  You then have a perfect fitting for your gauges.

Picture this.  If your on the economy side of life.  Get some of the largest diameter of PVC.  Split it as explained above.  Use a heat gun to roll it out flat.  Hot glue all of the gauges at one end.  Use heat to fold the other half of the PVC over onto the top of the gauges so that they are wrapped.  If required, cut more PVC, flatten it, and use permanent glue to completely enclose the wrap and let cool.  Remove the gauges so that you can use the molded PVC into your "ONE-OFF" fabrication.  If your not on the economy side, buy a sheet of ABS and apply the relative method.

Point of my story, answering your question....I use....whatever is needed to closely fit the gauges.