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I made a mold of my daggerboards, I thought I would share how I made the mold.

I took two 1/2 pieces of ply wood and cut out the rough shape of the foil. I then smeared them with thickend epoxy and stuck the foil in between so the 1/2 inch edge of the ply was touching the board. Once they hardened I had a pretty good copy of the foil shape, in two half parts. I then cut 100 MDF pieces the same size as them ply wood and ran them all throught my router table with the original plywood template as the template for my router bit with a pattern making bit on it (ball bearing on the bottom.) I made a simple jig to make this go faster.

I then stacked all the mdf on end and glued them together on a larger piece of ply. Sand lightly, paint with gloss paint.

I'll post pics later.


Look forward to seeing the pictures. Thanks <img src="http://www.catsailor.com/forums/images/graemlins/cool.gif" alt="" />

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