Here you can see that we didn't glass all the way to the edge of the foam, this is becasue later when we shape the foam this edge will get rounded over. We didn't glass these pieces together because we don't have enough room in the garage so we did them seperate and we will glass them together after they are glued on the duct.

Here is a template we made of the shape we need to make the foam for the duct. That flat spot on it is there because later on we will have to make a foam wedge to put between the foam and the plywood.

Now we drew the shape onto the foam. So we have a reference to go by when we are shaping it.

THen we used our router to take steps of foam out so that we wouldn't have to sand as much. For a jig we just used a scrape piece of foam with the outside arc cut in it. Then we would clamp this piece of foam to the duct foam and run the router against it.

Here is a close up.

Here we have cut all the steps in the foam.

Here we have the foam sanded to the proper shape.