Block of UHMW

Received a 610x610x38mm hunk of plastic from InterstatePlastics.com today.
The plans call for two 'Lower Folding Strut Recess Molds' per beam, but I plan on building all four beams in near sequence, so I'll need eight of these cut out later on. The recycled plastic is MUCH cheaper than the virgin equivalent!
The model resting on top was made a few weekends ago so I could get a better perspective of this piece.

More Templates

A couple more beam related templates using some off-cuts from the much larger beam template.
Today, I also received some price quotes for MTI Resin Infusion hose. (I was going to put the prices here, but thought it might be better if you contacted Juergen directly for a quote) 

He is planning a USA website launch sometime this January, 2013. This product appears to be very promising, especially for smaller - more detailed pieces like these beam internal sections.

Juergen Schildgen

President and CEO

German Advanced Composites Inc.
80 S.W. 8th Street, Suite 2000

33130 Miami, Fl. USA

+1 305 423 7151

+49 152 2950 2909

Email:  info@german-advanced-composites.com
Web:  www.german-advanced-composites.com

Paper Templates

Working with paper scale cut-outs is the cheap way to get the most out of your expensive foam!

Paper Templates for cutout orientation planning

First Check box!

This is really so trivial, but hey - you gotta start someplace and this is as good as any I suppose.

After marking and drilling the beam pin pilot holes and double-checking for accuracy, I have officially completed the first task.

Beam Template

November 17, 2012
Current space arrangements dictate that will build out the smaller parts, bulkheads, beams and etc. before moving to another house where I'll have more room to put up a temporary shelter or something large enough to build out the hulls and complete the build.

Meanwhile, after spending no less than 100 hours of reading the plans I'm getting anxious to start something!
So I picked up a 10' sheet of countertop laminate and a pack of carbon paper from Staples to make the beam template.
The plans call for using a thin sheet of ply, but I believe this will work better since it is somewhat more dimensionally stable and the reduced thickness will make it easier to be more accurate when making those critical folding strut pin holes.

Beam Layout