Starting to take the mold apart.
Well lets hope i don't need to make another mold.
The issue with the plug not coming out in one piece. When i built the plug The tip and tail are not perfectly in line with the widest point. When you bury the plug into the concrete you need to bury it up to the ends or the next pour will wrap around the tip and tail and encase them in that half. So what happened is that my first pour went past the widest part of my mold and held it in tight.
Here you can see the overhang it caused. I need to sand.grind this down so i can get the lead out once i pour that.
Going to let the mold dry then add some plaster to get it nice and smooth.
Mark and Matt helping my cut up the Cedar 2x4's for the keel foil. I would recommend using Cedar 2x6's or bigger. These worked but its very close to not reaching the sizes you need.
So after doing a fair amount of research let me share the different ideas and opinions with building this thing.
There are basically three different options for core material.
Mahogany- Heaviest/Strongest
Cedar- Medium Weight/Medium Strength
Foam- Lightest/Weakest.
Using Mahogany is definatly the safest route it is verry strong and verry dense. The issue is its heavy and verry dificult to fair.
Foam needs to be wraped in 7/10 layers of carbon to gain the streingth needed and not being up to speed with carbon yet and not wanting to drop alot of money on the carbon i decided to run with cedar to hopefully land somewhere in the middle. Not super heavy like mahogany but strong enough and easy to build.
I also am running 1/2" Stainless rod all the way thru the foil. When i ripped the 2x4's apart i made a notch in two of the pieces to allow my stainless rod to sit inside of it. When i epoxy the pieces togeather i will epoxy the rod in with them using High Denity filler same as i will to glue the wood togeather. I just like the idea of having the bulb rest on Steel Rods and not having that pressure on the light weight cedar.
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