Milling is time consuming, compared to hot wire cutting, but is very accurate, and allows rebates to be milled into the core for unidirectionals. Estimate cutting time for foam at 120 inches per minute, with passes 1/16" apart. On large foils this distance can be increased to 1/8", or even more, when cutting the flatter sections past the leading edge. Laminated wood blanks may require cutting at a slower speed.
Milling of large daggerboards is done at the shop rate of $60/hr for the first 4 hours, then discounted to $40/hour for the next 4 hours, and $30/hour for any subsequent hours to completion. Lamination of the blank, design/setup time, and lamination/fairing/painting are all estimated at the shop rate of $60/hour.
Packaged in plywood crate for the trip to England (shipping cost only $CDN 250 by the way)
Customer says:
"Phil
Just to let you know they arrived yesterday - look great, now to get
them laminated
Ross"