I was not completely happy with the first fiberglass donut I had.  And after working with TimK I was convinced that it was too thick (2 1/4") and a bit too small in diameter (not much, maybe 1/4" overall).  So, I decided to correct this and make a donut mold that I could use to make a donut that was a perfect match for the TimK Torso.

I started with a donut I had received from NormS.  He had already reworked it to reduce the height to 2" so that saved me a lot of time.  I created a profile template to "fill out" the diameter to the new size.  I used the lazy susan to spin that around the donut and added bondo.  After many repeats of this operation I had built up the donut to the desired profile.  After that I primed it with Duratec (a polyester based catalyzed resin primer).  I also wanted to modify the depth of the lazy susan recess.  The old donut's recess was a bit less than 1/2".  This caused the lazy susan to "stick out" of the top too much.  I wanted a 3/4" depth.  This will allow the lazy susan to sit low enough in the donut that a 1/4" thick CSS plate can be sat upon it.  That CSS plate will be just high enough to fit into the TimK torso's recess.  It's always easier to raise the lazy susan using spacers if needed.  But it's a real tough job to lower the lazy susan so I think the 3/4" deep recess is a good idea.  To create the deeper recess I first cut out the existing bottom.  I then flipped the whole thing over and set it on a flat surface.  The bottom was kept elevated at 3/4" above the table using a 3/4" thick board.  From the back side I bondo'd the bottom plate into it's new, deeper position.  After that I flipped the donut over and used bondo to fill in the gaps and shape the interior of the recess.  Finally, more sanding and polishing and the donut plug is ready for the molding process.

Here's some photos of the process of making the plug:

Shots of the donut after pulling it from the mold.  It's been finished and painted with a primer coat: