Some photos. Foam core prep was started with lining of the foam core with masking tape. Typically this step would not be required but in my case, the foam was very low density (<1/2 lb stock) and tended to fall apart. The tape added some resiliency so I could work with the cut stations.

Rib accuracy probably rivals laser-cutting. The Lost Foam method is worth the trouble I think. Weights are rather low about 20 grams each panel without the top sheet and socket installed yet.

I'll post final weights when I have the parts ready for covering.