When I bought my '69 AS it didn't have the bigger AC shroud around the AC unit. Then on my way to AR for a wedding the only remaining cover blew some where down the road. Ugh!
So through some contacts at te local marina I was able to acquire some of the styrofoam they use for floating docks and such.
The next part was more of an experiment than anything else, I had to measure twice cut even more times just to make sure I was close to the original as possible. I then had to look online for the how to on fiberglassing. Little did I know that fiberglass resin will eat styrofoam, back tot he internet. Ah, Ha!!!!
To use styrofoam you have have a medium that will not melt, solution wax paper. So, I covered the mold and went to work, albeit not the best looking thing but it works for what I needed.
Round two: Looking online for the bigger shroud and finding it cost way out of my price range I decided to make another mold. Back to the marina, bad news they had some foam but it was to small, ugh
. Another source down the road had the huge pieces, my luck held the owner was giving these away
. The piece I got was 1 foot thick, 5 feet long, and 4 feet wide. I had to figure how to cut this piece down to size. Chain saw works like cutting butter with a hot knife. After the rough cut and some major smoothing the final piece looks like this.
Next post: Fiber glassing.