ABS Plastic Forming

[schefft]

Step by step: (and what I would do different if I had to do it again!)
1) I used some poster baord to trace the curves of the floor for both sides and traced that onto fiberboard
2) I made a frame out of fiberboard (1/8"), and duct tape to hold it together
3) fiberglass matting was stretched and stapled onto the fiberboard. (should have just stretched felt over the damn thing, much easier to work with)
4) spread a whole s***load of resin on it (should have slowed down and done small sections to make sure it soaked through everywhere)
5) let it dry
6) spent days with the orbital sander trying to smooth it all out.
7) 1 gallon of bondo (if I had done a better job with the fiberglass I wouldn't have had to use so much bondo!)
8) cut the holes. (used a variety of tools, patience is key!)
9) attached indoor/outdoor carpet to the outside with carpet adhesive (dries slow but is almost indestrucable)
10) used an end board of cabinetry laminate for the face plates (very very very fine blade on a very fast jig saw or scroll saw)
11) tore the keyboard rollers off of an old desk and used them to make the cover slide back instead of hinging it.
12) solid piece of pine (1") for lid, cut to shape and routered the edges.

That's it so far.

So what do y'all think?