This idea has been bouncing around my head for a while, but I don't really have the time right now. I might need to draw something out, but for the time-being, I hope this outline will do.
The goal is this - super tight edges without the need for glue, but with a bit more flexibility. I think it would be more applicable to 3/4 wrap and would make for a 'one stop' cassette perhaps?
I probably need to mock something up, but imagine sheet of AL, cut to size and ready to be used as a cassette. Add two lengths of AL strips (25 mm x 3 mm), fixed along the two longest edge of the cassette base. Each strip would be around the length of the edge set - these edges would act like a retaining wall for the ply. During layup, the ply is added into the cassette and become part of the flash. The ply would be shaped as per the photo and would create the same result.
The addition of the ply make the ski shaped cassette and because it is ply, (1) you can cut to exact size, as it will give a little and still pull from the cassette quite easily (2) allow different skis to be drawn from the same cassette (3) 3mm ply could be easily milled so that it held the core in place.
Unfortunately, the ply would become part of the flash - which is wasteful.
Anyone think this would work?
