Nice build of an interesting subject Mike.

It brought back bad memories reading about your trouble with the paper templates you used to cut out the parts. I forget who told me about it but here is a neat trick. If you lay a photocopied page upside down on balsa and saturate it with solvent (like lacquer thinner) the image will print directly onto the wood! Not only do you not have to deal with the paper, it will also label your parts at the same time. The solvent evaporates too fast to distort the wood like water can. The first time I tried it I was blown away at how well it worked.

Also, if you have to make 4 identical parts you can stack and pin three blank sheets to your printed wood and cut/sand them all at once. I gather all my 2x's and 4x's together and lay them out on a phantom sheet of balsa within the CAD program. When I print the file I line up the corners on the piece of wood and do the print trick.