I am working on a custom vehicle and have large areas that require filling/sculpting. Basically I am cutting up a joe jet and comedy redoing the underside.

Anybody have any suggestions for a product?

I was considering green stuff, but that would be a lot of green stuff and not sure if would form the "bond" between peices I am looking for.

Any suggestions appreciated.

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I try to do a few things when dealing with large areas to fill.

1) Find something else to plug into the hole. This probably won't work in your case, but this is a great time to think outside the box.

2) Find a piece of the original or another one of those vehicles to cut a part from. Sometimes I'll look at other vehicles that have a similar look to the area I'm plugging and go from there.

3) Use styrene plastic to make something that looks like the missing area. Due to the varitety of shapes and sizes this plastic comes in I can get close to something just using the plastic. And people who work with it more than me can do some crazy cool things with it beyond my current skill level.

4) Worst case scenario, I'll use the styrene as a backer to the hole and sculpt over it. If you put a hole in a wall in your house. You don't replace the whole wall or fill it all with putty. You put some screen inside the hole and putty on top of it. That is how I use the styrene. I sculpt on top of it and try to match the texture of the surrounding parts of the aircraft.

5) Combo special: a little of #2 and some of #3, and #4.

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I agree with pluv. Use something solid from another vehicle or use styrene to bridge the gap which will provide structure, strength, and a surface to apply the green stuff to. Ideally you want to find something that won't need much filler when finished. When I'm using parts from different vehicles together to fill spaces or just to combine them, I make very small cuts, I sand, I snip tiny portions away, until it fits as close as possible. Its time consuming and frustrating sometimes, but it is worth it in the end when the pieces finally fit together nicely.

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I think I need more info to respond, to be honest. Because I'm picturing a number of different scenarios, and my advice might change depending.

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I agree with these.

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I've never finished any of the projects I've tried it out on, but I've used 2 Part Urethane Resin to fill in gaps...usually the cheap stuff you can get from places like Hobby lobby and such... it mixes quick, sets quick, and sands fairly easily. It's a liquid so you'll need to make forms out of tinfoil and hot glue to keep it from running places you don't want it to go...

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If you use to much green stuff it gets heavy pretty fast.

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drbindy is right; the question is too open-ended. However, if I were opening up the bottom of a jet and modifying it, these are the questions I'd have to address:

1) How much structure am I removing?

2) Are there mechanicals (such as landing gear) that will be damaged by the removal?

3) What material is the donor plane made of?

The material used in the manufacture of Joe and other 3 3/4" vehicles varies considerably. This is important because the material used will dictate to some extent the modifications made. If you don't have an adhesive which will bond your replacement structure to the existing fuselage you're dead in the water straight away. Also, the size of the gap you're trying to fill will dictate whether some .020" styrene is suitable, or .090" acrylic is mandated.
Add in questions about what tools are available to you, your comfort level with those tools, and what the goal is for the finished product, and you can see there's no easy way to answer the question.

If you want to send me a pm, I'll do my best to answer any questions you may have.

Styrene sheet.
Youcan either get it from a hobby store, or cheap, or even free as it is used in 'for sale' signs and other promotional signage.
You can get plastic 'for sale' signs usually for a buck.
Get cheap 'super glue' from a 99 cent store. Super glues are all pretty much the same, its how you use it. You need a clean mounting surface, or a lack of oxygen. It can turn most powders, or fabrics into solid shapes. Cyanoacrilate glue and baking soda makes a cheap. strong gap filler, and you can sand or sculpt over it.

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Thanks all, and yes, it is open ended as I did not want to share too much.
Overall though I am adding landing gear to a plane which is expanding the body a bit and creating gaps.
I will try some styrene and get creative with cuts.
Thanks for all the input.

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I personally fill in the hole with other plastic or just plane styrene and then use Bondo creme (comes in an orange tube in the car section) to fill the remaining gaps.

But if you prefer you could likely get the can of bondo putty and use a screen material for a base and fill the entire space with bondo putty.

I was gonna suggest using those 'for sale' plastic signs they sell at Wal-Mart, but styrene will do.

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