First CAD drawings. (that it coverted to pdf) I took measurements of an original cone (thank you very much, Christine at Estes! When you talk nice to her she responds very well! )
I then blew them up with a scale factor of 4.18 (5.54 / 1.325) with 2 views 90 degrees apart. [pdf 1 & 2]
Then I did them full size but printing them in sections 'cause my printer only does 8.5 x 14 max. Notice that the full drawing has 2" incraments. for the 2" thick foam. Oh yea...I also had to make a giant caliper. [pic 1]
I used the full size drawing on pic 1 to measure and cut the foam.
The foam was glued and stack with a 3/4" ply base plate. I glue the foam together with gorilla glue.
The foam was then turned on the lathe to the shape. Sounds easy but it's not! [pic 2]
Like how do you carve an elephant? Just start with a big piece of marble and remove everything that doesn't belong on an elephant.
It's just what I do.
Next was the hard part...cutting the eye socket. That took some head scratching to figure out but I got it. I used a broken band saw blade with duct tape on each end as a saw to cut the foam. [pic 3]
Then came the eyeball, that was turned seperately (it's good to have more than one lathe ) That was then Gorrila glued on. Now I tried to make the eyeball itself out of pink foam but I only had a small piece of pink left. Get it..."pink eye" ..... so I had to make it out of blue foam.