Two complex shaped foam pieces were missing on the plug. We used our new CNC machine to mill these:
Though the machine makes most of the work, a good sketch is always needed. And this isn’t easy. This is even more evident when three dimensional pieces are milled. We used a mixture between QCad and FreeCAD to design the parts (both open source programs).
The piece at the front of the cabin was straightforwad to draw:
The piece at the aft has a very complex shape: It has on the top a cone shaped section, which is merged to something that looks more like a trailing edge of a wing. Drawing a good transition between these two quite different shapes is challenging. We, thus, decided to keep the piece simple but still providing the basic shape. We will sand it to its final shape: