plastic_gorilla said:
...make a mold and then turn out masses of great stuff...
Hmm, I think you may be on to me, sort of...
I am thinkin', since I have to make 4 of these, that I would make a 'fold-mold'
Material yet undecided, (Plexiglass, thin plywood or ?) to use as a pattern for the folding.
Hard to describe, but like papering a fin, but then removing the fin. A buck or a mandrel, not sure of the correct term.
If I made the pattern or patterns correctly, I could make them consistent, repeatable, and may not even have to measure anything.
Then, I could 'turn out masses of great stuff' (yea, I know you were talking about foam, I'm just being punny)
Lay down paper--> then pattern on top--> fold over--> cut--> remove pattern.
Yea, it's 2:45 am, and it makes perfect sense to me.
Maybe I can come up with a better explanation after some Zzzz...
Definatly some good ideas on how to make it more rigid, keep em coming!
I'm liking the rib idea, seems the least difficult, though I never thought it would be easy!
Thanks again.