An MDF skeleton was constructed and glued together inside the lower hatch area. Quarter-inch MDF templates were glued around the port to create the desired shape. The skeleton was removed and the entire lower hatch area was taped with 3M 233+ masking tape. Be sure to overlap the tape strips by at least 1/2 inch.
Aluminum foil was glued to the tape with 3M Super 77 spray adhesive. A body filler spreader was used to smooth out all of the wrinkles in the foil. The MDF skeleton was bolted into place over top of the foil with tapered 8/32 bolts. Green blocks of foam were cut down and glued into place with 3M Super 90 spray adhesive. Any gaps in between the foam blocks were packed with modeling clay.
The entire back half of the car was taped off and covered with 6-mil visquine. The entire mold was saturated with fiberglass resin and allowed to dry. Six layers of 1.5-ounce mat were then applied to the entire mold and allowed to cure in the car.
After several weeks of drying in the car, the newly created fiberglass panel was removed and ground-down before Rage Gold body filler was applied to the entire panel. The body filler was sanded smooth and a wood template was made out of 1/4-inch MDF to trim around the port opening. The sanded fiberglass panel was set into the car for a test-fit. Notice that the fiberglass was cut away for the latch striker to press through.