I've always got by using celotex/kingspan foam to make plugs in the past but I'm now preparing o make my biggest plug yet as body work for a vehicle, its about 2m long and 600mm wide.

I also use Kingspan. On larger projects like bodywork I use a mixture of plywood, mdf, hardboard and kingspan for the areas with compound curves and detail. You can bend hardboard into quite tight curves if you wet it first. I also sometimes use "chicken wire" with a couple of layers of CSM to form a basic shape to work from. There is less than one sheet of 25mm Kingspan in this project (£25).
Hope that helps.

Warren

Carbon Copies Ltd

Cheers for that, I guess I'll just have to be very accurate with the wood before covering it in foam, really surprised you managed to do that all in one sheet of 25mm! Btw, my local wickes has 25mm celotex for £20, don't know if that will save you a fiver

Not all the pattern is covered in Kingspan. You have the thickness of the foam to play with (25mm) so the wooden former certainly doesn't need to be accurate. Just make sure it is undersize not oversize.

Carbon Copies Ltd

Hi!