This has been a great thread. I enjoyed it and will be trying some of your techniques.

Just a couple of thoughts, since I'm relatively cheap, I've been using filament strapping tape running span wise around the wing core instead of carbon fiber. I usually use two complete wraps. On a large wing three. It takes some planning as you don't want to cut the tape when you install servos. To further describe it, I run tape top and bottom around the wing from the center-top, around a wing tip, back on the bottom to the other wing tip then back to the start. I do this in two or three places then skin the wing. Seems to be plenty strong enough for Q500's. Originally I saw this used on the "Gremlin" combat wing years ago. On that wing you did the tape and then just covered the foam with low temp covering, no balsa skin.

I've also been embedding kevlar strips under the top skins along the aileron hinge lines for gap less hinges. As described in Phil Barnes video "Vacuum Bagging Made Easy". After skinning the wing you cut out a narrow section of the aileron on the bottom skin, then melt the foam from the bottom to the kevlar on the top skin. On the top skin you carefully score the balsa to the kevlar. I use a small thin jewelers file. It makes an extremely strong flexible flutter free hinge that is almost invisible.

I located the video you mentioned here and I plan to order it:
[link=http://www.airbornemedia.com/store/rv-index.htm]Airborne Media[/link]

The Phil Barnes video is here:
[link=http://home.paonline.com/hayman/PAGE2.htm]Vacuum Bagging Made Easy[/link]

I like Phil's video because of all the other techniques you can pick up beside just making wings. For instance he uses 1.5" square aluminum tubes from Home Depot filled with lead shot for weights. You can make them any length you like, very cool.

Ciao,
Stan