Just barely, before waking, I had a vision of me making the booster strut and exhaust nozzle cone assemblies for my SA-5 out of foam, using wooden templates and the hotwire cutting method, then glassing the foam.
I had to get up and get started immediately, because if it is as efficient and easy as it was in my vision, I can stop making these pain in the butt paper transitions and trying to get them all lined up perfectly!
I'll print the profiles on paper, glue the paper to some lite ply, cut each profile in duplicate, then assemble the templates as tracing stencils to guide the wire.
when the foam parts are cut out, I'll sand the sharp edges, then glass them. They can then be sanded to final specs checking with my caliper along the way.
The Rocket Gods have seen fit to shine their graces on me today by golly!!!
ETA: Just knocked one out using the quick and dirty hotwire foam cutter that I made the other day, by just holding the paper template on the foam by hand. It came out good enough to prove the concept, and they ought to look great when I do them proper with the guide jig made of wood. I have not even had my coffee yet, but if I had to, I could make this a usable part! It will even reinforce my quick connect piece nicely.:clap: