Work in progress.....
So far not so bad, managed to break one parting off / grooving tool but surprisingly didn't damage the item and I managed to pick up where I had left off.
Looking at screen grabs from the net, the size and shape looks about right. I had read on other forums that others decided on 1" stock but I wonder if it should be slightly larger in diameter. 1" it is at the moment.
I have the ear mould in hand and that looks good, a few more hours (weeks!) and we will see how it looks.