The top half mold is basically a repeat of the lower mold. I used Solidworks to create the solid model then it goes into Mastercam to produce the G code for the router to cut.
The tooling board is cut into its shapes then bonded together to create the the stock. Then onto the router for cutting time.
Lots of chips and fluff. It never ceases to amaze me how much waste there is, no matter how hard I try to get the stock as close as I can.
Its on the home stretch. Only the final finishing passes.
The final sanding and its done. Now I seal it then wax it. Time to lay it up.
Canadian long-ez 