These are the two halves in the mould. The extra red bits allow for internal lips for joining. I did plan to use tissue on the final layer for both, but it was so much hassle to get smooth i gave up on the lower half.
Trimmed up and ready for joining, which I've done already. It fits quite well up to the original plastic duct. The join wont be that smooth, but that's something I can work on over winter, maybe making the whole thing from glass. I took a guess with the amount of cloth needed, two layers of tissue, and one layer each of 100g and 300g matting.
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