Cross Sections / Mold Construction

After we completed the design for our canoe, we sent the files to a company in town called Gravity Works. They converted the files for use in their milling machine and on January 2nd we traveled there to have the cross sections cut. We had 62 total cross sections cut for the canoe and it took about two and a half hours to complete.  Mold construction began on January 3rd. We placed pieces of 6 inch thick foam in between cross sections and used a hot wire to cut the foam to shape. This process took a couple of days and then the foam cross sections were places on the track. Once all the mold pieces were placed on the track we compressed them together and began the process of sanding and patching to make the mold nice and smooth.