• This is an this an intake, so a smooth surface is important. Maybe I should make it in two parts, maybe using plasticine or wax over the foam?

  • I have done this by shaping blue foam and dissolving it out.

    As others have said you’ll need to put a resist on the blue foam, I used parcel tape with good results also

  • Use a thick layer of gelcoat on the finished piece and get that smooth. It's easier to get the finished product smooth with a bit of sanding and bodging than it is to make the mould/buck smooth and transfer that smoothness to the finished product.

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