So I've got 275s on my SSM car and there are no good looking flares available on the market for our cars. I've never done any composite work before but I'm pretty crafty so I'm going to try to make some flares. The project will consist of forming a die out of foam and body filler, making a mold from the die and then finally, making the actual flares out of fiberglass. Since I'll have the molds, I'd be able to recreate the flares and make them from any composite materials later.
So far, I'm simply shaping the foam. This is the fun part. I'm going to make two different shaped flares (one on the driver side and one on the passenger side) so that I can pick the one I like best and match it on the other side before making the molds.
Here's what the current flares that are made for a Miata look like. I think the rears are ok but the fronts are too small.
I bought some foam sheets from Fiberglast. You can see the Miata flare on the floor next to the sheets.
Next I placed the foam on the tire and started shaving off material from the back of the block so that it would start to go over the body panel. I also laid down a layer of masking tape and a layer of clear packing tape on top of that to protect the body.
Once I felt that the block was carved out enough, I used 3M spray adhesive to hold the block on to the body and I started cutting the foam with a serrated kitchen knife.
It's been a really fun process of subtracting material. I started sanding the 2lb foam with a 60 grit paper on a block and it sands really, really well. I have a feeling these will turn out nice.