Once the clamps came off this morning I fired up the air powered die grinder and whacked off the seams. Smooth and finished simply wasn't necessary as it will al be covered with the sculpting epoxy later today. If I needed more than two copies I might consider getting a scan done of one finished piece and then route the extra copies... but with only two knights to fabricate it is simpler, cheaper and faster to do the second copy from scratch. With a four axis MultiCam now officially on the way to my shop it may time to seriously start looking at one of those small scanners...
Before I put more work into the piece I always test fit to make sure things are right. I do make mistakes more often than I like to admit. But this time everything looks great.
Now it is on to the next stage...
-dan