In between working on the furnace, I also found time to build the flask (cope and drag) and support boards. Although I have all of the woodworking equipment at home to do this, most of it is put away or in storage since, as of late, I mostly work with metal at home. Sparks and sawdust don't mix well. Anyway, I just built it in the wood shop at TechShop.
Initially, I got a little carried away making it too fancy (as far as the interlocking portion) but then realized:
1) It is made of wood.
2) I will be pouring 1200 degree F metal into it.
3) Eventually, I will manage to set it on fire.
So I simplified the alignment guides based on a few pictures I saw on the Internet. I also made a small frame with the remaining wood. My intent is to attach window screen to it and use it to screen clumps out of the green sand mix which I should be mixing up next....