Les,
Nice find on the flying foam. Any idea what they charge?

Phil's foils wanted $1200 for a mold and $600 for foam cores.

I have not checked their prices.
I built a CB plug and mold combo over the winter, it's on my site.
I vacuum bag with carbon and glass.
I popped out two parts a few weeks ago and then glued them up,
and I looks good. I was not pleased with the stiffness so I will add a few more layers of carbon on the next one.

Here I a shot of the plug.

Les,
Heres the pics you asked for

First one is the plywood template. Scribed a line close and filled with epoxy and left on the board to harden.

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.

Picture of the two halves of the plywood template.

I plan on making both halves of the CB from the same mold, I used a piece of countertop material for the top part of the mold, clamped it together so I'll have a nice clean center line to join the two halves. Just going to flip them end for end to join. I'll make a template to make sure that they arent twisted when I glue the the halves together.

Bill

OHHHh! I see, you made the mold straight from the MDF. That does make more sense.

looking good!

Jim,
I should have boards for you by this weekend.
Bill

No rush necessary for the craftsman! The week I meant to spend fitting out the boat went to building a garden shed, completing a lift and then working on a truck. Best laid plans..