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As of September 10, I finally had all of the cross-sections cut!
I’d been working in the basement, since the stairs were finally done, but all of the pieces felt a bit damp (not severely so, just…not as firm as one might expect). I brought everything upstairs to dry out for the night before I started gluing the cross-sections to the profile. I’ve been doing that two-at-a-time, more than a little frustrated by how “slow” Elmer’s is to bond. Really, though, that’s just impatience talking.
As I’ve been going, I noticed that the thin cardboard of the main profile is actually bending a fair amount, which I’m going to have to figure out how to correct before I start filling in the foam. Would be a shame to go to all this trouble to achieve a fair amount of symmetry only to have my entire axis be wobbly!
I also had a minor crisis last night, when I realized that I had mislabeled cross-sections 25 and 27 (part of the “face”). I realized this when I went to put on cross-section 26 (i.e. after 25 had set) and it was larger than its predecessor. I checked my Blender file and all was well, but the profile I had in Blender did not at all match the profile I expected to see for 25, based on the printout template and the cross-section itself. Sure enough, I had mislabeled it (and 27) in Photoshop! Cue emergency surgery to slice that cross-section off of the main profile and replace it with 27.
(Bonus: In the background on the right, you can see the two toaster ovens that I’m going to use to form the plastic-warming oven for my vacuform table!)