Thomas,
The CAD work looks great.
It's humbling to see some of the crazy self-taught ideas that I thought up and tried on my Buccaneer project being adopted by folks that are way more experienced in this area of model building than I. I was just making sh*t up as I went along, but for the most part it seems to work. The laser surface detailing and the laser cut and perforated Airex foam skins too.
Interesting to see some of the improvements that you are trying, such as laminated hardboard vs. my foam poster board parting planes. I have modified my approach slightly by covering the foam poster board with the self-adhesive vinyl-cutter material before I laser cut the parting planes in order to get an easy release. The surface coat doesn't stick to the vinyl surface.
Keep up the good work.
Paul