Part 1: Fuselage and Tail
They started the project with the fuselage. They gathered cutting files from sections of a 3D model and brought them to their XL and Aero CNCs.
They ran into an unexpected issue with the segment that has the beginning of the tail rudder. The front end of the fuselage segment tapers outward and so does the rudder, which meant initially the piece was somewhat wedged in the foam. Thankfully, they were able to pull it out and remove the inner scrap without breaking the piece.
With all the segments cut out, they stacked them together to see roughly how all the pieces fit.
Video of Part 1:
With the pieces all cut out, it was time to glue the fuselage together. In its raw state, it weighs about 6.3lbs.
The next step was to construct the tail and the rest of the rudder. They began cutting the necessary pieces out on their CNCs and did a rough fit of the rudder.
Video of Part 2: