Over the last couple of weeks I have been working on the getting the molds ready and starting the layup for the new openings. It took quite a bit of work to prep the molds using Bondo but I finally got them shaped to my satisfaction. I then applied many coats of mold-release to the Bondo before I began the fiberglass work.
Initially, I opted to use fiberglass matt since it was a thicker material than cloth but that turned out to be a regular nightmare. The matt would not stick down unless I applied heavy coats of resin, which resulted in a big glob of material which I needed to sand off. I now feel that fiberglass matt would work quite well when a vacuum bag will be applied but certainly not for a wet layup.
Aftrer removing the majority of the fiberglass matt, l layed up fiberglass cloth in two layers and was very happy with the result. This first application set the shape of the opening. After it cures, I will turn the part over and apply layers of cloth on the inside surface to replace the material I cutout. Then will come the finish work (sand/seal/paint).
