Lancair Builders,

I have a task that's been troubling me for several years now...at least I'm claiming this as the reason for flying, rather than finishing the interior of my airplane!

I am trying to make a "plug" in the shape of the front and back edges of the door frame/fuselage intersection. My intention is to use this to make a fiberglass molding that I can cover with headliner material like I plan for the rest of the fuselage inside top. I have tried to "carve" hard Styrofoam into a shape that will fit the door frame, but it's a three-dimensional curve, and I was not able to produce a satisfactory part from solid foam. I then  tried to use some "weather sealant" spray foam, after taping over the subject area. This was a TOTAL MESS--spray everywhere except where I wanted it. The foam that actually got near the right location dripped off before it became rigid. I have tried modeling clay...way too much required, and too difficult to work with...etc...etc... Any ideas most appreciated on a way ahead...

Thanks in advance.

Bob