Thanks guys! Yes, it's quite a bit of work, but it goes fast once you've got the tools made and the process down to a science. You can save the tools for reuse on other planes.
I forgot to add one other bit of info...In step 7 when you glue in the 1/32" ply servo well walls, it is difficult to keep them seated against the foam while the glue is setting up. I used a piece of scrap EPP foam cut to size and jammed it into the well. The EPP (expanded polypropylene) foam has some 'springyness' to it and it held the ply pieces perfectly in place.
Could you also take a premade plate and heat it up to conform to the airfoil?
It depends upon the type of plate. I primarily use West Systems' 105/205 resin and it has a pretty low heat deflection temperature, so I suppose it could be heated and bent...I've never tried it, but I'm going to right now. Contact me via email if you would like for me to make the plates for you.
-Tom