Thanks Bdawg Atwell..
The plug is made just like a normal fiberglass plug but then.. the mold is made from rubber and not fiberglass.
From this epoxy is poured into the rubber and a tool is made. The epoxy tool goes into a thermal forming machine and the hot lexan is vacuumed over the tool.
Its VERY costly.. the tooling for the Nemesis cowl was approaching 1,000 dollars. The shear amount of material needed to make a mold that large is costly. The rubber came from Wacker, pronounced (Vockker) as well as the epoxy..
One could CNC Ren board OR hard wood to make the tool BUT one would need to be darn good at surfacing in a 3D program to make the part drawing. I can do that work now.. but could not then...
Never the less. it make a neat part!
Grim