Gary Austin let me use his original bungee covers. (Photo 1) Bungee Covers, note cracks around mounting holes and riveted repairs
(Photo 2) Plywood mounting board holds the bungee covers for duplication. I wanted to make the covers 3/8" wider to allow for some trimming to fit and close up the centerline gap between the L and R covers. Also, I added a 1/4 " shim under the center of the originals to give a bit of preload to the spring effect.
(Photo 3) Bungee covers are attached to the mounting board with 1/2 inch aircraft nails around outside edges and given first coat of wax.
(Photo 4) Then the waxed bungee covers are given two layers of fiberglass and the base box is bedded into the still-wet resin. In this photo you're looking at what will be the bottom of the finished mold.
(Photo 5) The first part being removed from the mold. It still needs to be cleaned, trimmed, painted, and cut into two individual covers.
(Photo 6) The finished composite bungee covers.
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