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Cone #2 turned out better than the abominable cone #1. Bevelling the edges 45 degrees like they taught at the welding lectures helped a lot.
Unfortunately it still had a pretty big seam and I don't have any putty. So I had to grind up some plastic, dump a little cement there and apply the resulting paste. How much should I wait before filing/sanding it down, so the polystyrol sets? I'm guessing a day? 12 hours?