To say the least, I ruined two pieces of fiberglass tonight trying to get one built. Is there any other material out there that might work for this?

Thanks in advance, Chris

Kennym sells templates for Reflex/ deflex.Just need a pattern bit and a router . Thats if your looking to make a form for R/F.

Try clear plexi-glass its a little easier to work with.

I use 1/16th inch aluminum strip.  Relatively easy to work with and durable.  Assuming you are talking about a limb width template.

I made my limb profile template out of formica, Most cabinet shops have scrap pieces they will give you or sell for cheap

Some good ideas here. I was using .043 clear glass on the first two, and I couldn't keep it from splintering.  

I make mine with .100 A-boo lam.

I like  .040 glass. Take a straight edge and a knife and score repeatedly along the desired edge. After a fair amount of work it will break cleanly along the scored line and you can do it very precisely. I screwed up a lot of glass trying to cut and grind it to shape. This way works perfectly for me.

Bonner