Photo # 1. And here is what the curved paper backer board looked like when removed from the car. This technique produced an adequate form, which held together, but I was very concerned about its overall strength and ability to hold up throughout the process of having padding and upholstery applied. I simply did not feel it was strong enough.
Photo # 2. So my next idea was to use this basic form, but to apply a couple layers of fiberglass cloth and resin over the top. This produced a very sturdy form which would have held up to a good deal of abuse, HOWEVER, when I went to test fit the completed form, I discovered the fiberglass curing process had warped and altered the form so much that it no longer came close to fitting back in the corner is was intended to cover.
Photo # 3. At this point I abandoned the use of card stock and went back to Taylor and Mangusâ€™s other recommendation for an even heavier weight paper called chipboard. I also decided to approach the mounting of the chipboard using a different approach which was to first install all the flat panels in the car and attach the chipboard to these panels. I made the flat panels from 1/8" Masonite. This pictures shows the installed flat panels.