Attached is a picture of another project from work. We cut appart the MDF plug from our heavyweight K1 that we made molds from this summer. The new design is a lightweight version with less volume in the hull. The blocks were mounted on the NC machine and re-ground to the new lower volume shape. This was a lot less machining than starting from solid cubes of MDF like we did the first time around.

The block were then mounted on the two aluminum box channels and reglued together. The tough part was getting the length right. At first we were too long. We put wedges in the ends and squeezed the blocks together. The epoxy mixture was thick enough so that after getting the length exact the glue kept squeezing out and the plug went too short. The blocks had to be pulled appart cardboard shims put in to get back 3mm of length.

If you look along the flange you can see error in the NC program. It kept forgetting that there was a flange and grinding the flange as it moved back to it's starting position. This had to be filled with filler (maroon mixture of epoxy, micro baloons, and cabasill)

I will be getting a full body workout with a long board next week

Jack