The two nose blocks need to be curved on the inside to give more foot room in the nose. I made a template of the approximate curve I wanted and then routed out the pieces within .2″ of the final required depth.

I have left them a touch thick so give me more leeway in making a nice rounded outer nose shape.

The curves took a couple of days to carve out. I tried various power tools and ended up using a permagrit curved file and just putting the time in. My curve isn’t perfect, but not bad and pretty good for the inside of a nose that will never be seen.

I spent a lot of extra time at the end getting the PVC foam sanded down with 120grit. I wonder if a better surface will take the micro better and have less air issues. I’ll try this for the coming layup rather than hardshell again and see if there is an improvement.

Pic 2 shows off my nice curves and pic 3 has more of a nose shape visible on the inside.

Route to the approximate depth

After a LOT of sanding

Check for a good fit