Foam

The sections are cut out from drawings and pinned on the high density foam blocks.  A band saw is used to cut the sections out of the foam.

Sections are cut slightly bigger than the drawing allowing a bit of extra foam for trimming purposes in the final shaping stages.

A small drill bit is used to make pilot holes in the foam at the reference points.  After that a large (25mm) drill bit is used to make the holes to the required size (The size of the pipes). Now the sections are pushed onto two steel pipes of 25mm diameter.  These pipes are used to keep the sections aligned.

After each foam section the corresponding hardboard sections is placed in. These hardboard sections are put in place as a guide and to make the shaping easier.