RE: mosquito bomber full size construction?
"Quote from online source."
The genius of the aircraft's construction lay in the innovative and somewhat unorthodox use of seemingly commonplace materials and techniques. The bulk of the Mosquito was made of plywood. Stronger and lighter than most grades of plywood, this special plywood was produced by a combination of 3/8" sheets of Ecuadorean balsawood sandwiched between sheets of Canadian birch plywood. Like a deck of cards, sheets of wood alternated with sheets of a special casein-based (later formaldehyde) wood glue.
The fuselage was formed in concrete moulds. Left and right sides of the fuselage were fitted with bulkheads and structural members separately while the glue cured. Reinforcing was achieved with hundreds of small brass wood screws. This arrangement greatly simplified the installation of hydraulic lines and other fittings, as the two halves of the fuselage were open for easy access by workers. The halves were then glued and bolted together, and covered with doped Madapolam fabric.
The wings were also made of wood. To increase strength, the wings were made as one single assembly, onto which the fuselage, once both halves had been mated, was lowered and attached.
Metal was used sparingly in the construction of structural elements. It was mostly used in engine mounts and fairings, control surfaces, and of course, brass screws.
The glue used was initially casein-based. It was changed to a formaldehyde-based preparation when the Mosquito was introduced to fighting in semi-tropical and tropical climates, after some unexplained crashes led to the suspicion that the glue was unable to withstand the climate. De Havilland also developed a technique to accelerate the glue drying by heating it using microwaves.
The specialized wood veneer used in the construction of the Mosquito was made by Roddis Manufacturing in Marshfield, Wisconsin, United States. Hamilton Roddis had teams of dexterous young women ironing the (unusually thin) strong wood veneer product before shipping to the UK.
P.S. Can't wait to see your's when it's done.