Here is the (near) end result of many experiments and a whole bunch of time. PU expandable foam applied to the fender then carved to shape. The whole thing is still a little on the fat side - cant take it any farther until I have the tires mounted on the front wheels (next week) then drop it on the ground. Its going to be BMW's turn at the Monterey Historics again one of these years soon (last was 1996) and I want to be ready when that happens.