The first step was to fabricate the forms over which the balsa will be molded. The method I used is very similar to that in the Hunt video. The base is fabricated from 1/2" mdf. The formers are made from 1/8" plywood. When making the formers, cut two of each, one for the form and one for a glue up frame (fabricated later). The easiest way to get identical copies is to glue pieces of ply together with 3M spray and then cut.

The formers were glued in place and 2# eps blocks were glued between the formers. A hot wire with a stand off riding the formers was used to get the eps blocks within about a 1/4" of the formers. This saved a lot shaping effort.

The best tools I have found for rapid final shaping are a Stanley sure form plane and a flexible sanding block. The plane is available at most hardware stores. I fabricated the flexible sanding block out of 1/4" ply in about 10 minutes and applied 60 grit paper, but similar tools are available from auto body supply houses. The length of flexible block should be such that it can span two formers. Shaping using this approach goes very quickly. I got each form to final shape in about 30 minutes.