Thread: Project $ 3 K Is Underway

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Don,
The process is really simple.
Basically you fab up a plug out Expanded Polystyrene foam, the white stuff cheap coolers and drinking cups are made of (there's a reason I didn't refer to "Styrofoam" but that's a whole nother story) to the shape of the inner tunnel.
You can get this from a variety of sources in sheet, block form.
Working tools can consist of any of the following-Bread knife, hacksaw blade, utility razor, band saw can all be used for cutting.
Rasp, surform, D A , 40-80 grit abrasives for shaping, finer grit for finishing.

Once you've shaped the plug to fit, you seal (assuming you're using Poly resin) it. Sealers would include any of the following. Water based acrylic enamel paint, Latex house paint, or even a coat of thinned Elmers glue. Absolutely no solvent base materials.

Once the sealer has dried/cured use of a parting agent is optional but recommended.

Lay up your glass over the plug, if the working side of the glass is going to be finished ie. exposed to open view, take appropriate steps to facilitate (build).

Allow the glass to fully cure.

Once cured flip the plug over and carve a basin in the center of the plug.
Fill the basin with Acetone and set aside in a well ventilated area away from sparks or open flame.

The acetone will dissolve the EP, you more than likely will need to clear the cavity and add fresh Acetone until the majority of the foam is dissolved. If you used a parting agent in conjunction, you should be able to break the plug free prior to complete dissolution of the foam.

Clean, trim, fit your new tranny tunnel!