: are those the mould pieces that are made out of 2'x2' MDF?? In that case the
: whole mould must be incredibly heavy!

Yes the plug and the mold flange is solid MDF. Believe me when they are all glued up this thing is heavy.

: how are the channel rails trued up first to accept that exact a formwk? from
: the floor?

Each plug block had two 3” channels cut 18” apart in their bottoms which were used to align them in the NC machine and again on the strong back. The strong back is two parallel angle irons clamped to a frame

Is the assembly moved around?

We have the plug and frame on dollies so that it can be rolled into a spray booth for priming. It take two to three people to move it.

: do you know what software is used to generate the original designs?

The owner is a marine architect. I believe he uses a high end hull design program but I don't know which one.

: be interesting to see/hear how they seam the inside of such a long narrow
: shape

I will be too. I know the rim the hull and deck while they are in the mold with a router. Apparently it is a very tricky step as one miss step and the mold gets damaged.

: Get to smuggle any 'seconds' out yet??

Given the costs of the materials there is no room for seconds but I do hope to get a loaner to try out.

: ps - any thoughts of mandrel winding that form?? be interesting to program in an asymmetric wind.

Don't know how you would ever get the mandrel out with a cigar shaped kayak. They do make "D" shaped spars and masts. I saw one of the madrals that stretched a small amount creating low spot near the base. The next winding got stuck and no ammount of heating and cooling could release the mast from the mandrel.

Will keep you posted

Jack