Originally Posted by schamberlin
Or should I cut a narrow deep channel 1mm wide and 3mm deep? On this axis the rod is very stiff and so it won't conform to the curve of the nose. I'd have to cut the channel very deep (much deeper than 3mm) in the areas of biggest nose curvature, the mount the rod inside it without any flex.
do this method. you will need to cut deep into the foam. if you have some carbon rods that conform to the nose, that would be best, but if you only have flat pieces, the method above will give you the most strength.