Thanks for the ideas on heated molds. I was thinking of getting a cheap used oven and looping air through a well insulated enclosure (heater duct) surrounding my vacuum bagging mold and back through the oven. Good enough flow should ensure a uniform temp throughout, and convection should heat/cool t...

I was also thinking of going with the routered channel and placing mold releas on the outside edge except for a few spots to hold it in place during profiling. That way the outside edge of the channell should define the outside edge as accurately as the cut can be made. I just got in a bag of phenol...

Thanks for the warning. I was thinking of routing a well in the unprofiled core and filling it with a flexible epoxy and mix of pheholic microballoons and microfibers to create sidewalls and tip spacers. Hopefully that won't create i'ts own problems.

I'm going to order some up and possibly laminated it with basswood.
It's expensive here, but will probably make for a strong and thin core.

has anyone out there used spruce as a core with any success?