All four beam molds cut out and (mostly) prepped

Once you start cutting MDF, you might as well do whatever you can to get it over with.
Man I hate cutting that stuff, it kills blades, makes an unbelievable mess and is just ridiculously heavy! When I was finally done, it took two hours to clean the shop since the dust just settles everywhere.

I ripped and cut all the battens and spreaders for both the top and bottom molds, so hopefully it won't take much to get them all put together whenever I get some foam.

Probably the most nerve wracking part is making sure the Upper and Lower holes for the struts are placed exactly where they are supposed to be. I still need to make the doublers for those holes, but I'll do that next weekend as I've had enough of it for now.

Anyway, here are some progress pictures:

This is the full size template used to make sure everything lines up in the beams before you start gluing things together.
I've called it the "Last Chance" template, I think that's appropriate.

Remember those Beam Molds I made last year? The ones that were not quite up to spec?
Well, I found a good use for one of them. I cut it in half to represent the real thing.

If everything is cut to spec, then the "Last Chance" template should line up with the upper and lower strut holes while matching the face and top of the beam mold which is represented here with the scrap piece I cut in half.

Looks good from this angle

Nice fit on the face and top

And more importantly, the holes line up just right!

I squared up two sheets and then screwed them together on the outer edges. Then I traced the template before adding in some additional screws near the cut off area. The Track Saw worked great to get the tops of the molds really straight before switching to a jig saw for the curve. The blue tape above marks the stopping point for the Track Saw.