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Making the moulds

To make the mould, stack MDF disks of decreasing size and then cover with automotive body filler.
From thinner material, cut a disk of the desired flare radius to use as a scraper.
Draw a stop line on the baseboard where you want the port to stretch to.

Ten things you will need ...

Ten things

 

Three moulds
Three moulds before any filler is added, along with the scrapers for each

 

Before sanding
Sand off any high points between applications

 

Smaller one
Another example.....

 

Cleaning up with a chisel
A flat chisel helps remove buildup on baseboard outside flare zone

 

Sanded
Sanded smooth

 

Whilst it is possible to use slightly larger MDF disks as you get closer to the baseboard, the savings in Bondo are minimal. It's easier to just make them all the same size.

 

Last update to this page 14th April 2009