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Regarding the mold, I was thinking about using extruded polystyrene, covered up with fiberglass. After covering the whole mold with fiberglass I want to put a thin aluminum/plastic sheet on top that can be covered with mold release wax so I can get the skis out of the mold.
I have a friend who does CNC commercial signs out of the stuff, and I could get cheap access to make 10-15 mold shapes out of 30mm thick polystyrene. I was thinking about it since the material itself would be much cheaper than using MDF boards, and having access to a CNC router would mean a lot more precise results than just cutting MDF with a jig saw.
Considering I am only intending to use the mold for vacuum bagging and curing at room temperature, I don't think there would be any structural problems.
I am also considering building each plate of the mold out of 2 parts since I can't seem to find any 2m long extruded polystyrene sheets; largest I have found are someting like 1.25m long. I was thinking about drilling 2 holes in eacch 1/2 finsihed plate and then joining them with 2 round internal wood spars, so I could have a finsihed plate; after this would be done, I could glue all 20 or so (depending on thickness) finished plates and finally cover the whole thing withh fiberglass.
Do you guys think this could work?