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I’ve been quiet on this front of late, but not idle. When we last left off, I had nearly finished gluing the cross-sections into place. Once finished, my concern about the main profile board proved well-founded, with the board making a gentle but noticeable arc from front to back. This meant the centerline of the entire helmet would be incorrect once finished. However, I noticed that I could manhandle it into correct alignment. I hatched a scheme to create a platform for the helmet into which I would drill regular holes for dowels that would enforce the spacing between each profile. After doing just the center two and two toward the rear (around cross-section 8), I realized that the dowels just weren’t rigid enough for the idea to work. They bent too easily, meaning the heavy mass of cardboard was better at shifting their alignment than they were at keeping it aligned. I ultimately went with a simpler approach and tried to fix each of the cross-sections in place by anchoring them to other cross-sections with masking tape. It mostly worked.
Next came the insulation foam.