Are you MatejO on RC Groups? That's great to hear that you are doing a similar thing.
Actually I get really good results using a small flat end mill with parallel passes to do the whole chord. The moulds need very little polishing to get them mirror smooth.
Also in practice I don't have the cutter step up around the LE and onto the flange. I use sweep on the LE curve to create a small "fake" surface extending a couple of mm above the LE, and include that in the geometry for the main surface cuts - so the cutter follows up the LE perfectly and lifts up on the fake LE lip before doing a direct move to the next pass.