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Just getting another panel would be best. You can modify it and use all the factor bolt locations making the install super easy. If you absolutely need to make a duplicate then here's the process:
1. Mask the panel [blue tape].
2. Get some tin foil, spray 3m adhesive on the dull side and stick that on the masked surface and spread that smooth.
3. Wax the foil surface, turtle wax is fine. Do a couple of coats and buff. This will act as a mold release so that you won't have to use a pry bar to separate the mold.
4. Apply resin to the foil, let it tack a bit then apply your fiberglass.
5. Now if you want to do it right apply enough layer to make it thick and non flexible.
SIDE NOTE: Masking and fiberglass should overlay to neighboring panels. The reason for the overlap and the thick mold is that you not going to use this mold as a replacement, you use this mold as you negative... which means more work.
7. Wax the mold up really well so that its slick.
8. Apply resin and fiberglass.
9. Trim edge and now you have to figure out how to attach it to the factory location.........
If your going to make a duplicate don't just make the first mold and call it a day. Your adding material to the original surface level then your probably going to spread some filler, when you done you would have added enough surface that it won't line up with the neighboring panel and look, in my opinion cheap. Do it all the way.
But honestly, just buy another panel from the dealer or go to a pick'n'pull, or find an online distributor. It'll safe you from a needless amount of work.
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