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using an allen key to mark the actual depth inside the edge
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Marking Out the mould edge with french curves
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the cut out plan ready to be glued to a sheet of perspex
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Cutting out the perspex template
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the cut is placed outside of the actual template line
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marking the corner blocks and drilling the inside corner edge to prevent the perspex from cracking
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holes drilled at the ends of 2 cracks which I made whilst drilling a hole for the jigsaw!
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the template all cut out and finshed, ready for tracing around
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the template layed out on a sheet of 12mm ply, the first of a three layer mould
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cutting out the first layer of the mould
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marking the model and the "L" so I know which side is which
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the jigsaw cut outside of the actual line
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sqauring off the edge to the line
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squaring off the edge of the plywood
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a better way to see the curves
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the first plywood layer is at a the first draft level
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all three layer are now ready for joining and squaring off
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Squaring off all three layers to the final edge. this is tedious work!
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sanding down wooden dowling to be used as assembly guides. They have to be a tight interference fit that can be assembled by hand.
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drilling the assembly beams and guide holes with a drill press to keep them square
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the cuts in the lower bouts on the top layer. This is for easy dis-assembly from the completed ribs
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the cut though the top layer on the upper bouts
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This mould was patterned from a few different ones I saw photographs of. The main things that was planned for was for easy removal from the ribs and accurate measurements on assembly
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