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Originally Posted by drunken monkey
I'm guessing that the bondo is just going to be used to make the buck, not the body.
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That's right, it'll just be the buck.
I looked at making the body in various ways and visited a few pro modelmakers for their feedback on various ideas. I guess I've got overly obsessed with creating an even shell thickness and smooth inside as I wanted to cast it in resin using two part silicon moulds but there are 2 main problems here:
1. Casting such a large mould shape quickly before the resin goes off, and
2. You need a lot of silicone for the moulds and at this size they become too flexible (wobbly)
The last guy I visited suggested my bondo idea was OK and that I should concentrate on getting the buck right first rather than initially worrying about the casting process. To this end I'll probably take a fibreglass mould off the buck and cast the body from that (in fibreglass too). I've done quite a bit of fibreglass moulding on my full-size car so it's something I'm relatively comfortable with - even though it's filthy stuff to work with!
My ultimate aim (if I ever finish this one) is to also make a shortened version of this body to make a Porsche RSK. The RSK had the low flyscreen and the same body but a 100mm shorter wheelbase which entails shortening the doors. I've been told the RSK nose was a different shape to the RS60 but I've looked at 100's of reference pictures and cannot see the difference myself.