Aaron had widened the front side panels at the bottom with a strip of aluminum. This caused the hinge to be offset to the left side. I followed suit and used the hinge as a datum line when making the form for the right rear side panel. Much of the shape was predetermined by the factory with the exception that it was longer and I tried to pull the shape of the rear section inward at the rear edges of the panels. Classic tuna-shape technology. I completely closed the gap between the existing panels and the rear tire. I had stumbled onto some information from teams racing Hayabusas at Bonneville that this one treatment really cleans up the air as it passes over the bike.
This picture shows the first of two female jamb edges that would have to be molded into this piece. This jamb is actually a continuation of the factory shape with the added width across the belly.
Test fit. Test fit. Test fit. The most repeated step ever.
The first six layers had been laminated and were still on the form. The form was removed after full cure.
Off the form and back onto the bike for another test fit. See the ghost line of the old edge?
After final shaping it's test fitted again and the Dzus fasteners temporarily installed.
In this picture...
...and this picture I attempted capture the body turning inward at the rear to recreate that classic tuna shape.
This is the second female jamb edge to be molded in this piece. Originally the left and right rear panels never touched but now they would share eighteen inches of mating surface.
This shows the final test fit of the right rear side panel before creating the form for the left rear side panel. Notice the aluminum widening strip on the front right panel and the close tolerances inside here even with the motor and suspension absent.