With the rear plug finished to a perfectly smooth Mack Truck brown finish it could then be waxed with a bunch of coats and clad with the gelcoat and the fibreglass that would then be removed to form the moulds for the rear body panels for the Ligero.
The process is outlined in the video below – First of all a thick coat of black gelcoat is sprayed onto the waxed rear bodywork plug. The wax ensures that when the time comes to release the mould that it will separate at the gelcoat layer. The gelcoat allows for a perfectly smooth finish on the inside of the moulds for the panels. Once the gelcoat is appropriately dry, fibreglass is laid over the top of it to create the rigid structure for the moulds.
Everything is then left to cure with a few strategic pieces of wood for reinforcement and rigidity, and some carefully made separations in the mould to allow the mould to be strategically released in pieces.
Once cured these mould pieces will be removed from the plug and then the process of creating the first rear body panels will begin. The plug itself will then become largely obsolete, which seems a shame after all of the hours of hard work that went into it. One of the crew at Joe Bradley Fibreglass suggested that it could be turned into a barbecue or a home bar! What do you think?