ORIGINAL: Trev
Don, could you please elaborate a little on that thin ply and balsa TE method?
The TE is made up out of a lamination of 1/64" ply underneath 3/32" (or so) balsa. Then when the edge is sanded down, the tip of the TE is only as thick as the ply. This results in a scale thickness for the TE. The disadvantage is that, if the upperwing fabric is semi-transparent, you'll be able to see the "width" of the TE would be visible.
I'm not absolutely dead-set on using e.g. wire, any other nice technique will be a welcome inspiration. The solder solution you mentioned also sounds interesting, is that silver solder or the standard stuff?? I'd say the latter is probably too soft to maintain its shape.
I was thinking of standard soft solder. It would indeed be "soft" and therefore easy to form. But I think that once solartex were shrunk around it, it would hold its shape just fine.
When I get back to Japan, I can try out a couple of techniques on my "practice wing." I'll try both the solder idea and the cable idea.