clyons you could use foam [builders] and f/glass --- acetone will remove the foam --bit of goo mess ---you can mould the foam once dry --- check out the old fiat 500 with bike engine on you tube --complete build. this is more or less the way racetech done his and his mate used vw arches.I also used foam[lots of dust]but was in too much of a hurry.I was thinking of the subaru style.cut arch [like bridge] another flat sheet cut out semi for wheel.check a few Banzai or japanese - motor mags all about jap cars

The model worked and so did the unwrap but the forms are very intense requiring some tedious welding, so that's that one in the bin.

Had a go using some steel framework to build the shape then used cardboard to get the final form. Much more successful, pictures when the results are worthy!

Cherry looks bloody fantastic by the way, well done!!

Negative Troy, no holdens over here. Will perhaps make the prototype and then use that as the mould for some glassing.

The other alternative of course is to go straight for a wooden mould. Will see how it pans out.

Any vk commodores over there?? that's what I used for the cherry bombs front flares. cut the front guards out and put them on the Cherry. KB laser guards where cut for the rear flares.

Thanks Chris, sounds like you have the tools to make the pattern. Get the shape you want and then unwrap it. If you can print it off you can glue the paper pattern to the steel and cut around it. If it's close enough you can panel beat the last bit.

I cut it by hand and marked the points out by hand, wish I'd taken some photos of the making to show you. Before cutting up the steel I made some paper models, printer paper's a fair bit cheaper than big sheets of galv steel.

Great trailer Dylan! I sent your items today................. Apologies.

Simon, I'm hearing you but unfortunately my strike rate of getting something remotely similar to the first is completely nil. Tradies of your calibre can probably do this on a Saturday arvo in the shed!

I use 3ds max, the same software that's used for games and special effects, it has an awesome feature that allows you to apply imagery to the model, UVW mapping. The basis of this function is to convert the 3d model itself into an absolute 2d model so you can apply materials and surface maps so that the model can be rendered to realistic appearance. its like producing a net of a three dimensional item.

This function can also be exported to produce line drawings that can be sent to a laser cutter.

I worked out a similar problem to make a front for my trailer. I marked up the profile to cut on the sheet so that it would bend up nicely into shape shown. The trick was to project the edge profile of the finished part onto a flat plane (the sheet). If you get the geometry right it's just a matter of cutting it out and welding it on, like I did.

How good is your maths? I imagine the flat piece of metal would look something like a smiley face. The trial and error method is to cut pieces of card out in the shape you think until you get a piece that forms the right shape when you stick it on the guard.

Do you use Solidworks? I don't know how to but I think it has a sheet metal function that might solve the problem for you.

If you're lucky my nerd gene will kick in and I'll solve it for you but I'm a bit short on time at the moment.

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It wouldn't be too hard to shape a flare from a flat piece of sheet. It would just take time.

You will need a leather bag filled with steel shot or similar and a pear shaped mallet to get most of the shaping done. Then a domed dolly on a stand and a plenishing hammer to get out any marks. It can then be finished with a panel file. No welding required.

Its a very similar process to flaring the original guard, but heaps slower.