Sounds daft but where'd you buy something like that warren? Google isn't assisting.

eta finally found it.

If you give me your email address I will send you pictures of parts that I have made,and explain I can't 

These are really handy for this type of work and cheap as chips.

Carbon Copies Ltd

Now that's a cracking idea, cheers Warren

I would split the project into two parts, the Fly Screen and the Tank Covers. Make up a three sided box from Hardboard or stiff cardboard large enough to fit the parts inside plus 50mm all round. Fill the boxes with expanding foam. Remove the Hardboard supports and start shaping. Even if it all goes horribly wrong all you have lost is some time and £10-£15 of materials.

Carbon Copies Ltd

Take your point but that's ripping someone off effectively and it's a massive load more work, as warren says.

Don't really see and advantage in that method. You are just increasing the time/cost/work involved. Make a Mould- Make a part from that Mould- Re-Model that part- Make a Mould of that modified part - Make the part from that Mould !!!!!!!!!! Why ?

Carbon Copies Ltd

Take a mold off original shape,then make Out off fiberglass then reshape or profile to what you want,then take a mold off that and your good to go.

Even if you get the foam profiled on a CNC (not cheap) you will still have to seal the surface and add some sort of reinforcement before you can take a mould from it. So there will still be a lot of hand finishing to do. I think you will be surprised how accurate you can the shape by hand. It should be possible to match the left/right profiles to within a millimeter or so.

Both really.

I think I'll do that - templates to get the dimensions right then foam and just keep measuring. If I can't get it accurate enough I'll have to get it digitized. It's the curved element I'm concerned about.