The molds are cut out first. They are made from white pine 1x10s.
The method I am using is to first transfer the shape onto cheap 1/8" ply. The ply is ripped to same width as the 1x10. The plans are laid over the wood and an awl is used to transfer the shape to the wood, one puncture every 1/2 inch or so. Then, I draw the shape on the ply by connecting the dots, cut to just outside of the line with a jig saw, smooth the edges to the line with a spokeshave, block plane, and sandpaper, then use that as a pattern to screw down to a piece of the white pine. Cut to just outside the pattern with a jigsaw, then finish it with a flush trim bit on the router.
Below is my first pattern. I was happy until I realized that I forgot about extending it up to meet the line on the plans that you see just above the top of the pattern. This is where the mold will rest on the building jig, so I had to staple on another little piece of wood to the pattern (not shown).
This time around my helper is seriously happy to help.
The first mold half came out ok.
Molds 2, 4 and 6 laid out. I had a few router mishaps as I learned about wood grain orientation issues and created some wasted wood, but all in all pretty smooth.
Half of mold 8 laid out on the plans to check the shape. I have opted for the wineglass transom and so am using the additional drawings for molds 8, 10 and transom.
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