Step 1: Build the Jig
Then I split the profile in half to attatch to the sides of the jig. This profile would provide the template I would use to carve out the material.
A piece of 1.5 inch Schedule 40 PVC is used to lay up the layers of foam and will also act as the barrel.
Step 2: Cut the Material
I marked the center point and cut a hole with a two inch hole saw for the barrel.
Step 3: Load The Jig
I stacked the squares of foam onto the pipe until the length I requried was achieved. The smaller circle of MDF went on. Then I got some help to compress the material to mark the pipe and drill a small pilot hole. I'ts important to compress the material a bit to hold it in place. The foam will not be glued until after it is shaped.