Has anyone made their own g/f boot box? If so, how did you make the buck?

Suggestions please, for suitable material, for making the initial "model".

Make the plug out of MDF. A router will make nice curved edges. Varnish in SOLVENT based varnish, not water based. Wax. GRP to make the box.

Or, varnish a flat piece of MDF and wax then make lots of flat sheets. These can be bonded together with GRP bridging paste, available from Halfords or similar.

MDF will give a matt finish to the gelcoat laid up on it. Use gelcoat mixed with easy sand filler powder and you can knock it back ready for painting.

It is a bit of a bodge method of making GRP but once painted it will look fine.

[Edited on 5-12-2008 by smart51]

Thanks for that suggestion. Probably more practical than using expanding foam. Might modify the basic MDF box, using filler for the internal radii.