Hello All, I thought I would share how I used my 3d printer to get a precise tip/tail shape on my master template.
I'm working on the template for my first pair. Its a half template that will be flipped to get symmetrical whole templates for the base shape. I first printed the shape split onto sheets of 11x17 paper and attached to MDF with spray adhesive. That let me rough cut the shape with the jig saw and then lay out and attach a plywood batten to do the effective edge radius with a router flush trim bit.
Then I 3d printed mini templates of the tip and tail and attached them to the MDF and followed them with the router bit. I messed up one of the screw holes for the tip template but it wasn't a problem since there were two more.
Overall this worked really well and required minimal cleanup after the fact. Just a quick hand sand to smooth it out and blend the part where the different operations met near the contact points.
3D Printed Templates
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