With the insides layed up this prep is for the hard points inlayed from the outside.

I drilled pilot holes in the five locations after ensuring both sides were the same size by taping them together and trimming. The hard points I cut out with a router and a metal cutting bit. Then a quick trim with hand tools.

Using the cut pieces as a template and a drill bit through the centres to position them, I marked the holes and the oblong. Then I VERY carfully set the router to the exact depth of where the glass starts on the NG30 and routed out the holes like making a jigsaw puzzle piece. I just carefully routed to the lines and ended up with tight fits for the pieces.

I marked lines on the circles so I could get them back in the same place and orientation.

Then I cut out 8 pieces of glass for the 4 ply layups. I used 45 degrees bias but the plans say anything is OK. This always takes a while and I used the taping technique to keep the weave pretty straight when the pieces are picked up. …probably over kill I know.

Match drilling

Hard points

Inlay and glass prep