22 Dec 07

Lots of good work on the mold today. The front is basically finalized; I spent most of my time working out the back and side today. I had to put a lot of wood on the floor today near the back, because we have concocted a new plan about how to mold the butterfly panels. The new plan is first to shape the wood mold to the shape it needs to be under the butterfly panels. Once this surface is correct, we will pour a 2-part urethane all over the area where the butterfly panels will be. The urethane will expand into a foam and create volume. From this foam we will sculpt the butterfly panels, and we will use the foam for the shape of a fiberglass mold which will fit in our Black Bros. press. This is a neat process which should save some time, but using it simply meant that I had to chisel, cut, grind, and sand away a lot of wood on the rear end that was built to the height of the butterfly panels.