Pictures
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The foam blocks were just glued together with the strongback inside to keep rigidity.
Here is a good view of the headbox bracketed to the I-beam stongback, and the glued foam blocks.
Shaping the foam.
More shaping...
...still shaping...
The plug has taken its rough shape.
Front angle view.
Rear angle view.
WICKED FAST!!!
Before laying the plug with fiberglass, we had cover it with epoxy, then apply auto body filler to give the plug a hard, strong surface. The epoxy is to prevent the body filler from "eating" away at the foam.
To make a mold of our plug, we had to lay-up half the plug with fiberglass so it can pop off. Before doing this, we had to construct a small table-like structure to support a flange at the mid point of the plug.
To release the mold from the plug, Mike Robinson gently taps the surface with hammer. Notice that the mold turns hazy white after releasing from the dark blue plug.
Our hard work, and 15 layers of wax, pays off. The mold releases from our plug with ease.