he uses a 2 part expanding foam to fill in the area to be used as patterns. first cardboard is used to trap the foam in the places to be filled. looks a little strange but now it’s ready for pouring.
This reply was modified 2 years, 4 months ago by mike sutton.
the foam expands quickly but you can only mix so much at a time so it requires several pours. obviously you need the foam to go higher than you want so it can be shaved down to shape. the last photo shows the next day when the foam hardened and the cardboard was removed.
finally time to start cutting away at it. Mike used a variety of sheetrock handsaws, body filler graters and sanding blocks to slowly form all of the premeasured radiuses from side to side and from front to back.
Mike layed sheets of aluminum foil over the roof and even though they wrinkle a little they really show the shape from the reflection of the ceiling lights. just another way to check. very happy with the overall shape of the roof and the rear window location and angle. that was my biggest worry.