8178 - yeah, that's the way I usually do it. it's not hard, but I always have a hard time sanding smoooth because of the difference in hardness between the dowel and the balsa wood. Plus, it's just about the cheapest way to do it.

Troy - Your way does look slightly quicker and easier, a little more money.

I'm still thinking that a a thin sheet of fiberglass or carbon fiber could be cut into shape and then a single saw cut is all you need.

Thanks to both of you guys for replying.