Saturn

build up with leather or bondo type auto body filler. or buy larger and carve to suit. I have no experience with cork in this application, good luck

1- really, any leather or material that you are comfortable with and can source. 2- also relates to #1. think total thickness and suitability for type of shoe and use. 3- the belly is where welting is cut from - toe puffs etc Flank leather also for building up lasts 4- sure, if it is all you can get - saddle skirting is cheep and easy practice material- hammer to compress. 5 - hmmmm... Mckay needle? There are dozens of techniques and many are mis-named. 6 - depending on your method it varies - however you decide to hand sew search here. The most important piece is a good stout knife for soles/heels & hammer. I'm sure you already have cutting & skiving thing leather skills/tools Saturn