Hi all, I'm looking for help. I'm making a mold for the seatback of my Tesla Model S. I've sanded the surface with a 1500 grit. It's silky smooth. I put modeling clay into the crack surrounding the seatback. I'm now looking to create the flanges for the vacuum tape. This design is a little tricky for me. I tried corregated signboard but with no flat surface on the underside. I'm having trouble getting it to stick. I'm now thinking of using pour foam to get my flanges. I'd wrap the piece in a bag, find a big box to where the foam will ooze out the sides of the piece and create the flange. Suggestions?

Hanaldo, you beat me to that one...    I tend to cut out a lot of smaller pieces of the Coreflute (Correx/Signboard... ) and to mix it with other materials, like PU sheet, plywood, filleting wax,  e.t.c.  I sometimes put steps and bends into the flanges, to get them to conform to the part.  It can become quite a puzzle --

I do not think I ever managed to set up a pattern-part for making a mould on just one unbroken piece of Correx ..  There's a reason the originals were made from thermoplastic mouldings or glassfibre -reinforced polyester..

(Complex shapes --- )

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