The Mould is Done
The end result, was a three-piece mould. Here it has been placed upside down, as this is the way the resin will be poured.

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The Moment of Truth
Alumilite casting resin was poured in the mould. Now I could see if a three-piece mould would work.

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Success!
Only three minutes (yes, 3) the resin has cured and the funnel could be removed. I now had perfect upper and lower halves for the funnels with all the holes for the rings and steps.

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Funnels Intro / Funnel Plugs / Cowling / Cowling Mould / Cowling Casting / Funnel Mould / Funnel Casting/ Funnel Assembly / Whistle / Rings / Final Product