Hi Alan,
my intention is to use, if advantageous, lead shot for all models, so far the Center of Gravity is achieved without additional moving ballasts.
Volume is the matter of concern since I found also that lead shots can be as low as 4.4kg/dm3.
I would like to avoid casting because is dangerous for non expert people, I would of course choose the slice method as I always use.
The particular AUSTRALIA II keel could made with a two parts mold including the wiglets.
Melting foam with acetone is damaging also the laminate and it is a dirty job IMO.
I would suggest a silicone mold as depicted below.
I will see what I can do to render the life easy. The keel could be an ‘added-on’ part as the red lined profile in the image below :
Cheers
ClaudioD
BTW : High Temperature (310°C) Silicone molds can be used also for ballast lead melting !