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First, thank you to all of the responders. Your comments help.
I can get to the stage where I have shaped the foam and attached it to the old vent using hot glue or two sided tape no problem. Bondo and shape to smooth inside and out is also a non-issue. This is where I struggle a little.
I understand Fiddlebog's reply that glassing is a bit like paper mache and I really have no issue with that and I assume it needs to be done certainly on the outside but also inside as well, correct? It's just going to be a little harder to finish it on the inside of the part.
Would love to do as Maytag suggests and build a part mold and I may try that but I only need one so using the original vent and simply glassing the foam scoop onto it is probably the best (easiest) way to go.
I will attempt to simply glass the foam scoop onto the vent and run the glass down 1/2 way on the neck or as little as possible so that the fit is still acceptable in the fenderwell. I'll show you the part as I progress.
Anything else I'm missing?
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