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The first attempt at a nosecone mold was to layup fiberglass on top of an existing nose cone. However, the mold tended to flex during the layup and cure because it was so thin.

The CAD model for the mold, with all the details.

On the left is the nose cone section, and on the right is the coupler section.
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The block of MDF being glued together before machining.The mold being machined on a CNC router.

The mold after being coated with gelcoat, and sanding.On the right, an accessory tool for nosecone layups

Closeup of an alignment pin and pry slot.

The second attempt at a nosecone mold was to cut it out of a large block of MDF.

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