1.) I assume you are doing all of this on a 3 axis mill. Is this mill special made to do this type of work (ie lighter duty cause all you are cutting is foam or wax or wood...etc.)

No.. the mill is a standard metal cutting mill... When it was
new, it went for ~$100,000... You can get the same mill
now for ~$50,000

2.) Did you think about directly cutting the female molds? I can see how with a 3 axis that might be hard.

yea.. we were going to cut the mold itself, then I got
a price for an aluminum 90"x13"x7' and bout fell out...
and they would be too big and heavy to vacuum bag.
I was told that building a few molds was not that big
a deal...

3.) Solid works. I assume you used the lofting command a lot. How did you decide where to put the guide points for the loft on each cross section? I keep looking for software that will do this like magic, but it looked to me like with Solid works you have to do it manually.

Your right.. Each cross section has 8 points... no more. no less
The #1 point on cross section A must line up with #1 point
on cross section B... There are no guide curves.

4.) How did you design that bypass? If you ever want to offset some costs I will buy one from you. What is the inlet diameter?

I just plan on making a few planes, but with the very
low part count, I may make a builders kit. (builder does
a lot of work)

I drew a AT450 (the biggest turbine that it will fly with)
and then drew a nice smooth curve around it. That's it.
I made sure to leave 0.750" gap.. No big deal..
All other turbines will just have more room.
It will most likely fly with AT400s or P160-P200
if we can get them.

I should be flying the first plane in 4-6 months, I will keep
this thread updated, but you are the first on the list to get one...

Thanks again
Eddie Weeks