We finally feel like we are making some real progress. The first side and it's trim ring are sealed up in a beautiful candy coating of spar. After several checks and double checks that we were orienting the plywood correctly, I used the trim ring to outline the second side.
Again we cut the outline of both the side and the trim ring at the same time.
And then raise the trim ring and cut out the inner profile.
I leave the line and use a belt sander to even out the curves. We finish this stage by filling any void in the edge of the plywood. I hope to drop the door before Thanksgiving and be prepped and ready to paint next week, which puts us on schedule to have the finish done before Christmas, then it is assembly in the new year!