Today (and yesterday) I worked on a proper jig to allow the foam to be placed with reproducible accuracy. Easier said than done, but I think I have it now. A ladder like structure with pins that poke into the foam, and a hard '0' point to reset the router in case I get lost and to verify that I didn't lose any steps (my table is a cheapie, I don't have a feedback mechanism on there).
Also the hard '0' gives me a repeatable Z '0', so it works for all dimensions.
After welding it up I placed it on the table and clamped it with some wedges to level it.
Then I spent hours and hours on tuning the toolpath for the blade run. It took
4 hours before to get one side done, now it's down to 1:36 or so. That should keep the router a lot happier too.
My new ball bit finally arrived.
Tomorow I'll be doing the next test run, I still have one more billet that I made up like that last one, good enough to test with. Then we'll try something radically different.
