Please note that it was FOAM posterboard that was used. Not the flimsy paper thin stuff. Aluminum sheet would work well, but it is usually cost prohibitive for a hobbyist. The foam posterboard would work very well for your application.
I think i am going to try the foam poster board. Give it a shot. I should try these ideas because they are inexpensive compared to the sheet metal. I just know the sheet metal would work perfectly.
I guess ill try going to target or wall mart to buy the board and the clay.
The panel has a pretty heavy contour and i was worried that the poster board would not take the shape of the panel.
ALSO THE BIGGEST Reason i keep asking questions about the flange and leaning toward the sheet metal. On some of my parts i am going to keep the flange on the final part to work as a plug.
CLASSICBIKE, I am SO tired of your smartass comments! If you are going to grouch then give me your BS, your replies are spoiling this thread! I don’t know much about composites and trying to learn.