Just put a new LED taillight on my bike. only thing is that it is no where near the style of the old.
I also want to replace the turn signals with LED units next the new brake light
so, looking to make a new tail section around the light. any recommendations?
Take a look on youtube on how to make custom speaker boxes. The technique should be simular for your round tail light.
http://www.youtube.com/watch?v=DzZO3M1oymQ&feature=related
Great Stuff. You know, that foam-in-a-can. Use it to make the form.
Spray a glob of it on, let it dry. Use a rasp, cheese grader, or heavy sand paper to shape it as needed.
If there are low spots, repeat.
Once you've shaped the foam into the shape you want, glass over it with a fiberglass patch kit- available at any auto parts store.
Then sand, Bondo the imperfections, finish sand, and paint.
use something like this?
http://www.partsamerica.com/ProductDetail.aspx?MfrCode=BND&MfrPartNumber=762&CategoryCode=3269
That link doesn't go anywhere meaningful.
SVreX wrote: Great Stuff. You know, that foam-in-a-can. Use it to make the form. Spray a glob of it on, let it dry. Use a rasp, cheese grader, or heavy sand paper to shape it as needed. If there are low spots, repeat. Once you've shaped the foam into the shape you want, glass over it with a fiberglass patch kit- available at any auto parts store. Then sand, Bondo the imperfections, finish sand, and paint.
Makes me want to fab something up for the sheer helluvit. 
The former model car builder in me already has the skillset for the finish work. (I think)
Chicken wire and remnant fleece from your local fabric store does well for speaker boxes, not so well for smaller projects.
I've used the green foam that is made for flower decorations. The dry gritty stuff. It's super easy to cut and shape for the mold and it doesn't dissolve when the resin hits it.
If you want to use it as a mold more than once, coat it with car wax. Otherwise just put the FG/resin right on it and it will break away.
Hocrest wrote: I've used the green foam that is made for flower decorations. The dry gritty stuff. It's super easy to cut and shape for the mold and it doesn't dissolve when the resin hits it. If you want to use it as a mold more than once, coat it with car wax. Otherwise just put the FG/resin right on it and it will break away.
I've had luck with this method. I glued aluminum foil to the mold and was able to use it several times.
SVreX wrote: That link doesn't go anywhere meaningful.
sorry...it asks for zip code? enter 49428
Ok- that stuff will work fine over a form.
The Great Stuff foam I am suggesting will be the form. That flower styrofoam others have suggested will work fine as a form, but it will be harder to shape in your situation. You can leave it in when you are finished, or gouge it out if you prefer..
The Great Stuff can be sprayed directly on what you've got.
Then, use the stuff you linked to (what I called a patch kit in my earlier instructions). Or, you can buy the other kind (resin and hardener in one can, plus small fiberglass mat). Both will work for something that small.
For something larger... say a bumper for a E30 to clean up the aero and mount a splitter to... would you use multiple applications of cloth+resin? Will I need to move out of my house for 3 days while it cures? How would you make stronger bosses for bolts to go thru?... can you embed aluminum tabs and have it adhere or would the stuff not stick to it?
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