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I had a similar situation with a Ford Transit Hood (look I have gone all American) As this was a "one off" this is what I did. Made a good quality Mould for the outer skin. I then continued as I would for a full Mould ie leave the Hood in the Mould fill in any holes etc but instead of making a Mould of the inner skin, just lay up 2 layers of 380 grm Chopped Matt with some Black Pigment in the Resin. Once cured, trim and do any cut-outs etc. You now have a inner skin that is slightly bigger (1mm ish) than the original but provides the stiffness and mounting points for the Hinges and Catches but at a fraction of the time/cost. Bond the two skins together and job done.
Carbon Copies Ltd
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