How did they mould the wings?
They have a set of moulds, originally made by Dave Rutherford. Basically it's a wooden box containing an inverse wing (ie with the smooth shiny bit on the inside). There's one mould for each wing on a car (ie 4 moulds) and there are 2 sets of moulds, one for the narrow-bodies cars, and one for the wider Plus 8s and later Plus 4s
To make the wings, firstly you clean up the surface of the mould and then coat it with a release compound that ensures the new wing won't stick to the mould.
Then you apply two layers of neat resin (a two-part epoxy), which provides the smooth outer layer - the so-called 'gel coat'. When you mix up the resin, you can add the appropriate dyes to get the final colour you want.
Pieces of woven glass fibre matting are next applied, with the pieces criss-crossing each other to provide a matrix of fibres for strength. The matting is bedded in with more resin, and you keep going until the required thickness is obtained - thin for the race cars to save as much weight as possible, thick (about 6mm) for road cars.
Once you're done, the mould is left for a few days for the new wing to cure properly and reach full strength before removing it.
Then it's simply a question of trimming the edges of the new wings to match the car onto which they are to be installed, bolting them into position and you're done!
I'm sure an experienced Morgan body expert could do it relatively quickly, I reckon I must have spent about 10 hours on each front wing and about 5 hours on each rear.
