Creating a fiberglass snowmobile trailer (aka - cutter)

Step 6 Ears and Tail

While we wanted swept back ears, we did not want the lid to hang up on them when it opened. Eventually the top and back surface of the ear foam was covered with fiberglass, the foam then completely removed from underneath, ear canal dimples were cut into the sphere of the head and more glass applied to the underside of each ear.

The tail was made of 3" thick foam, made by layering 2" and 1" foam together. Curves were in each section, with new sections at different angles to give a 3-D curve. To get a more or less round tail cross section, rasp file the 3" X 3" cross section into an octagon, then rasp that into a 3" diameter tail.

Care was taken that the tail was far enough out from the rear right haunch that it would not hang up when the lid opened. I then touches the torso between the rear haunch and front shoulder to prevent too much stress traveling along the tail to the back. In reality, three layers of fiberglass later the tail and lid are so stiff that this contact point could have been eliminated and the tail left completely free of the torso.