My boards are a sandwich of 2 1/4" sheets of foam.
I cut outthe shape of the line of the flip tip in 1/4 plywood - make 2. I make a rounded fliptip that follows the end of the board. I mark and cut this shape from the bottom sheet and then sandwich the boards together.
When I put glass on the bottom I put the plywood on top of the breather fabric and tape it in to position. When the vacuum presses down on the plywood it makes sure that the glass follows the fliptip edge because generally speaking glass doesnt want to.
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