The first step is constructing a building frame or strongback. Care must be taken to ensure that it is straight, square and level. Then mold stations are transferred from full size paper patterns to 3/4" plywood. The molds are then set up at the locations on the building frame and every thing is again checked for straight and square. In the photo below you can see the molds set up with a string line run through holes in each one to align the centerlines.
Below we are resawing teak strips to laminate the inner and outer stems. This bandsaw is a 42" Tannewitz built in 1963. We acquired it at an auction last year and have rebuilt it. The blade travels at 8800 feet per minute and with a 7 1/2 HP motor cuts through large teak boards effortlessly. We installed new bearings and tires and trued the tires and rebalanced the wheels and the result is a truly magnificent machine. They don't make saws like this in China.
We screwed blocks down in the shape of the inner stem and then laminated both the inner and outer stem at the same time with some plastic between them to prevent epoxy gluing them together.
After the epoxy cured we removed the clamps and shaped the inner stem to the correct size.
Here we have let the keelson into the molds and clamped the inner stem to it and the strongback. The molds have been checked for fairness and beveled as needed and have had battens screwed to them to keep them properly aligned.