I'm beginning to think building with foam is a realistic solution.

Once a person is properly tooled, this technique may even be more affoardable. However, in some areas of modeling, this application would never work. I do believe classic pattern lends itself fairly well.

I think I'll be looking into this, and learning how to make molds. Don (Frequent Flyer) has been willing to share his expertise on several different threads.

Foam core flying surfaces sheeted with lite ply seems reasonable.

I appreciate everyone's input. If anyone would like to chime in with anything else- feel free.

Brian