Soul Cycle Mothership, a molded fiberglass speaker cabinet for bicycles.

Step 19 Cut inner panels to seal the left and right speaker cabinets

The panels are polycarbonate, which despite being impact resistant, is quite flexible. In one of the pictures you can see how I stiffened it with ribs on the inside and outside surfaces. The ribs on the inside surface are also the shelf that rests on the Xtracycle snap deck.

I used thickened resin fillets to bond the polycarb panels to the fiberglass shape. I roughed up the polycarb around the edges and used glass strips to strength the fillets further.

Comments

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how did you get the right shape for the inner panels?