Pattern measuring 9 feet by 14 feet had been fabricated and machined in San Clemente, California. A sturdy metal frame was welded to support the TCC-1055 polyurethane boards. The pattern was machined in a single set-up, laser tracked and hand surfaced prior sending it to our plant in Tijuana for vacuum forming tool manufacturing.  Method of tool fabrication was chopper wet out for its speed and consistency. Being a vacuum form tool, tool integrity was crucial. Four layers of about 1/8” of an inch thickness was applied every day, followed by a inner wood stiffness structure with plywood followed by a final FRP layer to water tight the tool. Prior de-molding a custom metal frame was bolted. This project was completed within a six week period