Anyway for the benefit of others here is how I did it without the pain. Sorry if this is all too obvious to anyone, like I said I thought about this for quite a while before coming up with this one.
1. Make two plates like the one below from 5mm aluminum.
2. Using M6 nuts and bolts drill and attach the plates to the front (firewall) and top of the scuttle.
You will notice that the plates have two fixed bolt holes and one adjustable one (slot), fix the bolt in the slot at one end or the other depending if you want to widen or reduce the width of the scuttle node cone etc.
3. Carefully measure and mark where you will be cutting removing material.
4. Remove the plates and cut through the areas underneath them. (I used a rotozip drill bit in a standard drill).
5. Replace the plates and cut the rest of the material away.
The piece will now be in two halves but held together by the two plates (effectively jigged).
6. Loosen the bolt in the slot of each plate and widen or reduce the width of the piece to your requirements.
7. Tighten the above bolts back up the piece should now be in the exact position you want.
8. Using the wet lay up technique put enough material in place to be able remove the metal plates without the piece distorting or moving out of true. Allow to fully cure.
9. Remove the plates and again using the wet lay up technique apply enough material along the line of your cut to give the piece its original strength back.
10. Finish the top (gel coat) side as desired (filler, gel coat. what ever)... which leads me to my next question:
I have used filler on metal car bodies before but never GRP. Which brand type should I use or should I use something else ?
[Edited on 15/2/04 by givemethebighammer]
Rescued attachment jig.JPG
