Robyn,
Been thinking along the same lines as you. Only I was going to use aluminum flashing around the inside of the existing flair. Then fill in with two part foam, sand to shape, fill with Bondo, sand, then pop a mold off that to make fiberglass parts.
Just haven't been able to get my Roundtoit out of the tool box yet. That and where I live they don't allow working on vehicles. . . . .
"The Constitution is not an instrument for the government to restrain the people, it is an instrument for the people to restrain the government."
-Patrick Henry
A5150nut
2006 K3500 D/A
94 6.5 4x4 5spd Sold