I'm interested in what others do for construction of plugs, to see if there is a better way of doing it.

To make a fuse or wing plug "quickly", I use a CNC foam cutter on extruded polystyrene (blue foam). I then seal the foam with a coat of latex paint to reduce some of the bubbles that I see when applying epoxy directly to the foam. After the paint is dry, I then mix talc with laminating epoxy resin and coat the foam plug. This gives me a good primer-type finish for coarse sanding. The final step is to apply a layer (or a few) of epoxy gel coat, which is then sanded and polished.

Doing the plugs this way saves the time of not having to laminate the plug with fiberglass (and sand and primer and sand, and sand...), but I still get a tough durable finish for the female mold making.

Anyone see any flaws in this, or suggestions for a better process for plug construction using foam?