Originally Posted by chetosmachine
2 parts then join will be far worse than 1 piece core. Been there, donde that.
Depron, or xx psi foam, wil be far weaker than rohacell (at same density!).
If you want "A class" tails, 1 piece milled cores is the way to go.
If you just want tails, 2 piece core is convenient. But they are heavier and weaker.
Been there, done that too but if you don't have a machine for cores it's do-able. I have also hand shaped rohacell and cellfoam cores for solid core molding. The hand shaping seems like it would be a lot of work, but it really isn't. I can make cores faster by shaping by hand than by running my CNC... but they're a bit more oversized, which means more foam compression, which means more core weight.