Interesting about the 1st plug warping. I remeber reading somewhere about the first Duffy's being asymmetrical. I guess thats why.
They made a rough model and then put up a plastic building for a boat shop. They built a wooden plug of poplar, called "popple" locally. They worked for almost three months on that plug, starting at 5 in the morning and working till 4 in the afternoon. Because heat built up in the plastic building during the day, Richard had to open the end flaps, to keep the temperature even. But one weekend, he left for his National Guard duty and forgot to open the flap. When he returned, the wood had warped. Sick at the thought of three months' work lost, he almost burned the boat. but his then-wife suggested he wait till morning, and he had the sense to take her advice.
The next morning, Riley and Richard decided to fix it up as best they could, take a mould from it, and then leave it till the next year. "We faired it up and filled and sanded it," Richard recalled, but admitted, "It was never quite as good as it had been."