[jberg]

Looks like you are doing a similar project like I do (if I understood right).

I made first wooden/foam (polyurethane) buck and finally pull a mold out of that (not completly ready yet).

I spent a lot of time trying to make that plug surface perfect and that is a nightmare if you have wood/foam plug like I have.

My main problem was that no matter how nice surface you make that wood sections will be visble after few days. Wood and foam just act differently in different temperature/moisture etc.

If I started now all over again I would add few layer of glass mat after rough finish of foam. That could made that plug more solid so that there is allways same material under filler.

If you like to know more about my project send me a mail.

There is also some pictures about my plug/mold in my callery.