I took off the peel-ply and cleaned up the fiberglass a bit. I’ll need to do a bit more work to clean this up, but it made a big difference in the door stiffness already.
I picked up some two-part expanding polyurethane foam at TAP Plastics and poured some in a box that looked about the right size to form the oil cooler plenum. This needs 24 hours to cure before I can start shaping it. I fully expect that this first piece will be practice, and I’ll have to make another plug before I can layup the fiberglass over it.
