First I drew the part in Autodesk 123D, generated the cutting plan in CamBam and imported that into EMC2.
Then I started cutting the part in urethane foam board.
As the part is now cut on the router I removed it from the foam, to reveal my complete part.
Next I put the part into my casting flask and packed it out with Petrobond casting sand.
Note that I'm leaving the foam part in the mould. This will be cast using the lost foam method, where the foam is vaporised by the super hot aluminium.
<End of Part 1>