First, gut the back end to remove the light weight foamy stuff. Hardware won't attach to it very well.
Next, light weight filler. Tom@Manners sold me a box of his light weight filler material years ago. Whips up like instant spuds.
Once it cures, in the mill to be cut:
With two pieces now, I lay up some carbon ribbon to cap off each side. The ziplock back is just a divider so they don't glue together. I soak it down with mold release prior.
Knock em apart and get to sanding.
Sanding is all done, so its back in the mill for the machine work to fit the hardware.
Old legacy photo of what were after:
A finished example:
Next, light weight filler. Tom@Manners sold me a box of his light weight filler material years ago. Whips up like instant spuds.
Once it cures, in the mill to be cut:
With two pieces now, I lay up some carbon ribbon to cap off each side. The ziplock back is just a divider so they don't glue together. I soak it down with mold release prior.
Knock em apart and get to sanding.
Sanding is all done, so its back in the mill for the machine work to fit the hardware.
Old legacy photo of what were after:
A finished example:
. Your hillbilly ways are better than mine. 
