After cutting out the three leading edge shapes I used my bench drill press to drill holes through all three parts while they were clamped together and then used a pair of #10 wood screws to fasten them together. Then I moved my portable work table outside the garage (to minimize the amount of sawdust that ended up in the garage) and began sanding the three blocks. It took about 35 minutes of sanding (Image 1) but the end result was three leading edge shapes that are identical (Image 2). In the end I chose the bottom two pieces to use as the skeleton for my plexiglass form becasue I thought the countersunk holes I made in the top piece were too deep. After some careful measureing to be sure the parts were aligned I glued and screwed the 2 x 4 and the two end pieces together.
Using a Disk Sander to Sand all Three Shape the Same
