Sorry I just can't help myself. This is my niece and I think she's about the cutest thing ever to skip along on this planet. We had just finished a little shopping trip for her 9th birthday. We were taking pictures of her with a new set of junior golf clubs and she started messing around with my pilot hat and was practicing her "pilot announcements". I snapped this picture between her giggles. I can see this coming back to haunt her at some high school graduation ceremony!

Here's a test-fitting of the modified tank plug. I used duct tape to tape a few straps to the fuselage to rest the tank on. This allowed me to position the tank more-or-less where it would set when permanently mounted. I fiddled around with the strap length until I was satisfied with the tank height and then took a few pictures.

The angle of this picture isn't quite perfect, but what I was trying to do was to show how the taper of the tank closely matches the taper of the fuselage from the firewall to the instrument panel. It really came out nice as far as I'm concerned.

Here's one view of the new foam plug as compared to the original aluminum fuel tank. You'll also notice that I rounded over the corners of the foam plug. It's generally considered good practice to radius the corners of fiberglass molds because it's difficult to do sharp corners.

Just another view of the new foam plug as compared to the original aluminum tank.

The next step in the process of making this mold was covering it with fiberglass cloth and hi-temperature polyester resin.