Hansli, Thanks. I'd like to hear about your experiences too.
Builder, it's 2-part Bondo, but probably 3-4 major applications from a couple of different cans. Sometimes the hardner has been pink, other times blue. When I vary the amount of blue hardner to get different working times the color can range from sea-green to blue.
If you look back at my first pictures in the thread (a different gun), you can see the layers on the butt end and how I built up Bondo on the off side so I could remove wood to create castoff as well as raising the comb.
The forend started as a splinter. If I used only Bondo, it would wind up 75% Bondo and probably be too fragile to use as a pattern. Notice Chuck extended his pattern butt with wood as well as Bondo. I started by grinding a couple of flats on the forend wood, then gluing a pine strip to each side. This gives a better frame to support the glass.I've ground the forend down to approximate the final shape and feel during shoot-testing. That's why it has the stripes. Before I send it out, I'll beef it up more so it holds up well; the extra wood will be easy to remove when the stock comes back.
