Posted by: Mike Randall | June 21, 2009

Cutting the moulds

A couple of weekends ago we had a long weekend (Queens Birthday). We planned to go down to my brother in-laws farm. He’s got a nice big shed and its on 40 acres. I could make as much noise and mess as a liked. I decided this would be a good opportunity to cut some ply bulkheads!

I loaded the car up with 6 sheets of 15mm ply, 5 surfboards, bikes a guitar, dog, family etc etc and headed off to Apollo Bay for a busy, but fun weekend. I wish I’d taken a photo of the car, it was a bit overloaded.

There had been a bit of preliminary work before we headed off though. I’d traced all the moulds from my MDF templates and double checked for any inaccuracies. It’s easy to underestimate how long this takes and I spent a week of evenings getting everything drawn up before we headed off.

This was well worth the effort though as when it came time to cut it went pretty quick. I used my rough cut with the jigsw then router and flush trim bit to get everything neat and accurate.

First sheet ready to trim

First sheet ready to trim


Mould No 4 completed

Mould No 4 completed

I managed to cut out moulds 1-6 and the transom guides, as well as surf a few great waves and generally have a great long weekend.


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