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Once completed, the final form can be removed.

Cool Pics BD

If you guys check out sharky's website www.sharkymarine.com

I think he has photos of the building process along with descriptions of each photo

Excellent job explaining the process. Simple terms and unclutterd visuals.

Thanks. Gettin' kind of bored today.

Vacuum Bagging. Notice the Vacuum Port towards the upper left.

Typical Tool On a Frame.

Male Plug after Machining:

Female Tool Made from Plug.

COOL!!!!
Thanks bajadaze.
I'd love to get a look at the gantry mill they use to shape the foam. I'll bet that something.

The company I work for built their own plugs from plywood, finalized the configuration and had molds pulled from that. We weren't building anything as large as a hull but it did serve the purpose.
We design and build training simulators for the military and these were the basic interior shape of an M1 Abrams tank turret. After the glass was pulled from the mold an cured we bolted all the equipment into/onto it.

Thanks Iggy!
Here are some pics I found. These things are awesome.
Sounds like cool work you guys do. We design and manufacture aerospace, primary and secondary composite structure both commercial and military.