Now you can start to see how much the guard is coming out over stock. Where the masking tape is, the guard went straight down, now instead has come out on an angle well over an inch.
Test fitting the wheel, you can see that we're getting pretty close to the size we need to clear the wheel/tyre combo.
On the second furthest right cut, and the furthest left cut, you can see that the lip has been ground down a bit on an angle by the grinder to keep the shape of the guard a little.
Next step can be done by silicon, or by welding. I'd suggest the latter, but we didn't have the time, nor care for it. See below for more info.
We didn't show it, but the inner guard and outer guard were tack welded together, and were stopping additional flaring. We had to cut these tacks, and remove the offending pieces of inner guard. This now left a gap between the inner and outer. Unprotected metal + moisture = rust, which most ae86's will have enough of this to start with. So we sealed it up with silicon! Simple!
On with the fibreglass! Remember, wear gloves, and dont rub your eyes when you're handling the stuff. It hurts, trust jesus!
With the fibreglass on, and now sanded back, we started with the body filler. Sure, we put heaps on, and 90% of it is going to be sanded off anyway, but we didnt have time on our hands.
After a couple of layers of filler and sanding, we were getting fairly happy with the shape. Dremel with a cut-off blade was then used to neatly cut (lol) a better shape to the guard.