The 24" main nosecone after sanding. Matt really enjoyed working on
this, as it provided the opportunity to pack about 2 pounds of foam
shreds into the treads on his shoes, so that he could track it all
over the house, before realizing it was there.
Matt shows off the precision crafted tool used for delicately shaping
the main nosecone.
Here you can see Matt covering his arm precisely with pink foam. This
is a precision operation, if you want even coverage.
Matt delicately shaping the main nosecone. Note the use of precision
instruments -- we're picky about scale and only use the most accurate
devices available. (We don't call him the Master of Redneck Engineering
The beginnings of the main nosecone.
Nosecone mold half sitting in the redneck curing oven, waiting
for the high-tech thermal enhancement closure to be lowered.
The halves are left in the oven for 60 - 90 minutes (hey, the
thermostat is tempermental), until the epoxy reaches the green
Untrimmed mold halves, cured to the green (sticky! and firm) stage.
Mold halves, post-trimming. Such a fun job!
Bolting the mold halves together, so that a layup can be done
over the seam, then it goes back into the redneck oven until
the nose is fully cured. Notice the strict adherance to OSHA
guidelines, especially in terms of the non-slip footwear?
The oak master (Rick did a really nice job) and its first offspring.