My Rotor Harness (which turns out is the older Rotor KickAss, not the Vulto) has a soft squishy foam cone in the boot which does nothing but form the pointy tip of the harness. The Woody Valley Tenax Harness has a plastic shell which can be used for storage. I want the same functionality from my Rotor so it's time to make a fiberglass boot cone.

I plan to use the stock foam boot cone as a tool to make a plaster-of-paris mold. Once I have the mold made I can pull as many parts from it as I desire (or as others want to finance ;-) .) My flying buddy Joel hooked it up with some Teflon tape which I used to laminate and seal the foam cone:

In progress:

Finished laminating with tape, ready for molding:

Tomorrow I will go into the shop and start building the mold box. I hope to get everything ready to go, so when the north winds return I can be ready to pour the plaster. I don't want to miss any of the dwindling number of flying days we are getting out here.

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