After much waffling I've finally got an approved Q40 design based on Mike Arnolds AR-6 Endeavor..

To start with, the plug will be made with formers and foam.. Assuming everything goes well I'll look at an aluminum mold at a later date.. I'm doing a couple different wings to try before moving forward with a wing mold..

I sent the DXF file out to the laser cutter last night so hopefully next week I'll have some pics of the build..

A special thanks to Gary CAD work, it turned out way better than I could have hoped..