Here is what the seat side frame pattern is looking like so far. This will be the top side pattern. There are 17 separate pieces here, all loosely assembled on a base plate. Many of the pieces required curves to be cut in two different dimensions. Once this is glued up, all the features get added, such as the lips along the edges, the lettering and the feet.
There will be a corresponding core that will form the underside of the seat frame. There is a corresponding piece to each of the 17 pieces which will form the same parting line for the core, but looks like an impression of this top side pattern. You can see the pile of them just to the left.
This is the most difficult pattern I have done. It has been a crazy amount of time so far -- over a hundred hours. A lot of the time is set up, measuring and creating drawings. I am trying to make it as robust as I can, since this will be used for more than a couple of seats -- 24 just for Coach 9.