Optica Moulds

Here you can see the plug and open mould for the duct/shroud. The plug is made from circular wooden disks aligned with the wooden dowels, then planked with 3mm balsa, sanded, sprayed, waxed and moulded. The canopy plug (not visible) was made from insulation foam, fibre-glassed with one layer of cloth (to make it stronger as it was so large and difficult to handle). Reference marks were added before moulding (eg incidence lines and window openings) so that they would be repeated on the finished product and aid construction.