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Message: <blockquote data-quote="g36 monkey" data-source="post: 1026977" data-attributes="member: 10997">I've been talking with mold engineers at work to make sure I don't have any issues with this.  Because of the shape, the scoop should be really easy.  Waxing it like crazy, putting it on a piece of plywood, then laying out some material on it to make a basic mold.  Make it good and thick.  After I pop it off the scoop, then I glass some wood to it to make a box for added strength.  Fill any voids and gelcoat it, then finish it.Then I could start casting parts out of it.Your louvers would be more difficult because they have the cuts in them, I could talk to the guys at work, I'm sure someone would have an idea.</blockquote>