Then cut about 70 3/4x2X12 pieces of mdf on the table saw - took about 10 mins. Created a simple jig to hold the mdf pieces, and ran the router with a pattern bit past them. Each piece took about 3-4 secs, it look longer to put the part in the jig and screw it down than it did to route it.

Glued them together - see picture.

Sand and paint.

1 half female mold done in about an hour.