I went to a plastic company this afternoon that uses santoprene and had a chat to one of the guys on the floor about what I want to do.
He was running santoprene and the grade he was using looks and feels exactly like rubber.
He says santoprene will likley tear if I try to stretch it too much, and from what they use he said "PVC74" would be best.
But they did not have it as a sheet, they only had it as virgin material.
So I guess I will have to look at that as an option also.


On my way home I happened to drive by a company that deals with pouring urethanes, (What are the odds?)
I had a good chat with them and after looking at a few samples I think I have decided on how to make my part.

I am going to try to make a mould for the 2 covers (Driver & passenger)
and use a product they have recomended. "Eratrowel MT80A"
So I will call the sydney office during the week and hopefuly order 1 or 2kg to test.
I may use an some asbestos cloth from a fire blanket or fibreglass exaust packing to line my part for increased heat resistance.(This will probably end up being a whole new can of worms)

So I guess it will be a few weeks until I can post up any more success or failure as I have alot of work ahead of me.
But I want my part and I want success.
I am starting to enjoy this project as it is a good learning experience.