Doc,

I have been watching this thread with interest. I have been working on someting like this and using a method very similar to what you are doing. My project is a 42" wingsapn Yak 54 for E-power (3-4 cell li-po). The difference is that I am using hard board. The stuff is cheep, but hard to work with, and I may cut the formers from wood (I have done the profiles and cruches from hard board)

I was planning to plank the thing with balsa, but may go with flower shop foam. I used CAD to generate the patterns.