My first thought was to make a plug out of doam and then pull chassis from that but I quickly abandoned that idea. It would leave you with a rough outer surface. Instead I use an existing chassis as the plug.
![Image](http://i403.photobucket.com/albums/pp115/Drusky1979/RC%20Model%20stuff/IMG_7529.jpg)
Wax on wax off, I apply wax to every bit of the chassis and then polish it off. I do this a few times till she's slippy. I then seal the holes with plasticine so the epoxy doesn't get out of hand. I wax my work surface too.
![Image](http://i403.photobucket.com/albums/pp115/Drusky1979/RC%20Model%20stuff/IMG_7530.jpg)
![Image](http://i403.photobucket.com/albums/pp115/Drusky1979/RC%20Model%20stuff/IMG_7535.jpg)
I mix up my epoxy resin and get to work. I've already cut my glass cloth more or less to fit. I put 4 or so layers of cloth on, it is quite tedious work, you have to continually dab the cloth into those tight corners and make sure it hasn't pulled somewhere else.
![Image](http://i403.photobucket.com/albums/pp115/Drusky1979/RC%20Model%20stuff/IMG_7531.jpg)
Once the resin has dried I trim the excess off and pop the glass off of the chassis. It's quite thin but nice and smooth.
![Image](http://i403.photobucket.com/albums/pp115/Drusky1979/RC%20Model%20stuff/IMG_7533.jpg)
![Image](http://i403.photobucket.com/albums/pp115/Drusky1979/RC%20Model%20stuff/IMG_7534.jpg)
I'm not planning on making lots of these so I choose to use polyurethane foam glue to strengthen the part. It's quicker and easier than multi layers of cloth.
![Image](http://i403.photobucket.com/albums/pp115/Drusky1979/RC%20Model%20stuff/IMG_7536.jpg)
![Image](http://i403.photobucket.com/albums/pp115/Drusky1979/RC%20Model%20stuff/IMG_7537.jpg)
![Image](http://i403.photobucket.com/albums/pp115/Drusky1979/RC%20Model%20stuff/IMG_7538.jpg)
After popping the strengthened chassis off the mirror I fill the cavities on the lip with body filler and sand it smooth.
![Image](http://i403.photobucket.com/albums/pp115/Drusky1979/RC%20Model%20stuff/IMG_7544.jpg)
![Image](http://i403.photobucket.com/albums/pp115/Drusky1979/RC%20Model%20stuff/IMG_7545.jpg)
I after that I waxed the chassis again along with the mould, put the chassis back in the mould and glassed the other half. Once dried I strengthened the new half with PU foam as before. Hopefully this week I will be able to have a go at making a chassis.