Having just finished taking the last of my car’s panel moulds (9 moulds in total, months of work) I’ve moved my focus onto some other parts I need to produce before I can start to finally infuse parts and assemble the car.
I’ve started working on the front underbody/splitter.
It’s a single peice, 1850mm*1200mm with a diffuser fore of each front wheel, so it’s a fairly simple shape, something very much like this:

I’ve started making the plug out of 12mm MDF, which I’ll spray with Durabuild Surface Primer* to seal it.
I require the underside to be nice and smooth, which is easily done, but I also need the first 100mm or so of the top side of the leading edge to be a moulded surface.
Can anybody offer any advice on doing this? I’ll be using infusion to make the part.
What I have in mind is a two part mould - one for the bottom surface, which I’ll infuse first, and one for the top part. I could either infuse the top part seperately and bond on to the already infused part, or lay it up wet and vac bag it somehow.
I’m not sure how clear I’ve made my thoughts to anybody who reads this, but do offer your help please! Any advice at all would be great.
Thanks,
Alex
*Off topic, but does anybody else use this product - I’ve tried it before but it seems difficult to work with. I found it hard to get a good finish.