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Here are a few pictures of the CNC in action.

I hope to expand this section to discuss different foam types, and core preparation techniques for each type.

All cutting so far is with DOW Floormate 200-X. I have tried a piece of Knauf Polyfoam but this varied in density through the sheet and so proved nearly impossible to use (well, I gave up anyway)

Basic Steps are:

Block Out
   

Cut the main Panels
 

Cut the other Outer and Tip Panels