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the technique is really quite good and I am learning as I go - simply put, the mistakes I have made are not using enough CF at each stage requiring me to have multiple (unnecessary) stages - not a biggie, just taking a bit longer!
FYI - the Wing is 120g - tail feathers are 15g - the first part of the stiffened fuse is 48g leaving me 62g to play with for the servos/Rx/battery/front fuse sections - it seems like we are on track to get close to the original BAMF AUW weight of 245g - there will be some length trimming and sanding of the fuse which will save a bit more weight too.
The front fuse section is 15g - when added to the main fuse the total is 63g - the AUW for the wing/tails/fuse is 198g - double checking the BAMF weight, my wing covers have a note for 252g (7g heavier than I thought) - so I have 54g to play with for the servos/Rx/battery/nose ballast.
I also used the forming mould to drill the wing mount holes - should be nice and square.
I have epoxied in the wing nuts and am starting the cleanup process the negative side of this process is the outer surfaces are not facing the mould so do require more effort in cleaning them up - I will not go silly, but a tickle up is required!
I glued the front fuse section to the main fuse and checked the nose cone - the nose cone is the least smooth of the parts so I will see how it cleans up and whether to use it or not!
Not great pictures, but this morning I prepped the horizontal stabiliser for fitting to the boom - left to right looks good, but the critical alignment of the horizontal stabiliser with the wing is the biggie - as far as I can see we are within 0.5 degrees (which is probably better than before - nevertheless less I will recheck once the glue sets.
Chipping away with the basics - the horizontal stabiliser was previously changed to above the boom so refitting it under the boom meant I needed to swap the control arm to the other side - printed a new one - fitted both stabilisers - so far so good!
The 4 servos, Rx and battery are likely to weigh 50g - I am roughly just under the original weight of the BAMF ship (without nose ballast) so it looks likely the overall weight will be a tad higher - my boom is probably the culprit making the tail moment a bit higher.
I said I was not going to go overboard on the finishing, but one thing leads to another and the filler came out!
There are reasons to use that proper tooling. But as you have shown the added benefit might not be worth the cost and time. i think you 3D printing and male molds are getting you 90% of the way.
On another subject I see you are using cardboard box as stand off for your fixturing. I've found that cans make much better fixturing. While not Jo-block anything that has to go through high speed canning machines actually are pretty precise. I normally see my food cans with a tolerance band of less than 0.006mm
@Konrad - that is a great tip on the cans - my DAD is a perfectionist and I aspire to his traits, but it seems 90% (maybe 95%) is about me with the time available!
I'm, no pro - Did I mention I hate drywall? I've done about half of the house now. Slowly getting better. Will probably go back to the first room and retexture and repaint as I find that room a bit embarrassing. LOL