I wasn’t going to add but I’ve read this a few times.
As stated, laying up a custom nose bowl is the perfect and ideal way, but a big project and exposure to mistakes is high for a first time. I can make a plug for a small part. To make a plug and mold for a big part takes a craftsman to not be grinding and filling the final part.
Just an opinion, but if I had the dedication to build what you are accomplishing, I would modify an existing bowl as Stewart mentioned.
If you make it in-house rather than solicit a vendor...
To add size in any direction you can pick the flattest/straightest few inches and cut it in half. Move the sections out to the appropriate size, and then fill in the space to connect to the halves back together.
(The artists in this realm are the rod guys. The (now) simple example for them is to chop a top. You cut the door pillars and move the roof down, but the pillars have to line up. So you dice the roof into 2 or 4 sections and line up the pillars. Then add material in the roof to connect the parts again)
If you’re working with glass or fiber, I’m sure there are examples of this on YouTube. Heck, probably with aluminum too.
This video isn’t totally related, as he is splashing an existing hood for a plug. But, it’s a good detail on how to layup a part from it. (The company may also have plug-making videos using foam)
https://youtu.be/UgKvDw1E60E
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