Now the original never had a roof panel, so this is something that I will need to design and build totally from scratch. The design aspect I'm fine with, and I'm sure I could find a creative solution for creating a 2D cross-section and polurethane foam plug, but I wanted to find out if there is a better way to go about it? I realise MDF etc. are good options for flat areas, but are there any other good methods for building something like this?


Also, on an unrelated note, I could do with some business advice. I haven't been operating as a business for very long, and having never taken on a project like this before, I'm a little bit unsure on how to quote for it... Normally I work out material costs and try to estimate labour time and come up with a number from there, however I have no idea how much either of those things will end up with this project. It's a large project and will involve a lot of time I'm sure, so for those of you in the industry: how do you quote or charge for a project where you are unsure on how much you need to charge to be profitable? Last thing I want to do is underquote and end up having to pay for this thing out of my own pocket, I need to make sure I make a good profit on the job.