While not exactly offering any tips and techniques here, some are being requested on Rusty's current build - the Calypso.

I received my World Engines Calypso kit. While I wouldn't describe the kit as stellar in original quality or current state, it should be salvageable with some restorative work. Sheeting on the wings is 3 mm so somewhat thick by today's standards. Fortunately the foam is 3/4 lb. I've yet to weigh them but a good sanding should bring them into shape. The stabs look like they were chewed on by a big dog [:-] - plenty of "tooth marks" and the sheeting is cracked in a few spots (see photos). Again, some TLC should make them usable.

The fuse fortunately remains to be built and although some of the wood has seen better days (more dog chomping), the dents should disappear in the build. At least the kit makes for a good set of templates for a fresh kit which I'll make for posterity. On to a few questions:
[ul][*] The cowl is rather thin and cracked in several places. How would you go about restoring it? Should I lay more glass atop in thin layers and then resin the inside again? Maybe some CF on the inside? How best to lay it in? I'm not sure but I think this is a PU/glass cowl judging from the colour (haven't done the scratch test).
[*] I inserted one of the 1/8" ply FW's into the rear to give it some shape as it is rather distorted. I was considering making a FW ring to glue permanently into the cowl and then screwing it into the FW from the front through the cooling slot and nose ring. Any recommendations or suggestions on that?
[*] Although the wing tips indicate the top and bottom of the wing, there's no indication on the location of the landing gear or if any blocks have been installed. I'd like to install retracts. Would someone be kind enough to provide me with the measurements for locating these? (Rusty, Chuck?)
[*] The wing has two ply dihedral braces. Rusty/Chuck did these pose any issue in the production of the wing tunnel for the pipe?
[*] My kit is designated as the "sport" version. I'm not sure what the difference is between this and the "non sport" (or Hanno) version I presume - any ideas?
[*] I've seen the wing with strip ailerons (e.g., Rusty's) and then with more of an F3A aileron setup out of the prop wash. Any recommendations on which to go with? The latter could be produced without too much work by cutting them out of the bonded strip ailerons to the wing TE. I'll be using dual aileron servos.
[*] Finally, although asked before, does anyone have any plans for it? The best I have seen are the reduced scale drawings that come with the Model Tech ARC although I think the Aviomodelli kit came with plans. A set really ought to be made if no proper ones exist.
[/ul]
Chuck,

I received the piece of Kevlar - much appreciated! A piece will be used on the fuse header tunnel. BTW, my kit shows a couple of pieces of 3 mm (1/8") balsa used as a floor for the fuel tank under which are the two bottom nose blocks (MK style) where the header sits. Did you feel any need to substitute that balsa for ply? Will the Kevlar be sufficient to keep the heat at bay?

Also, did you run into any issues with the installation of the RE YS? Does the cowl enclose the engine? Did you use a regular fuse top header? I'm considering the same setup.

Here are some pics of the chomped kit...