Kent
While I very much do respect you and your opinion, I really do because I have always asked and listened to the older guys when figuring out how to do something, I do know there are other ways to do things. I did come up with a way to make a fast, cheap and perfect mold. Found it by accident actually when we got a kitten 3 weeks ago. And with the CNC machines and 3d printers becoming extremely cheap I think its all doable. I already 3d printed a CNC machine from my $200 printer. The automotive collision industry already has different kinds of foams that are low pressure and structural. Most of the companies are always willing to email you back. From what I have been reading and experience in building things its better to improve the process than to change what its made off. Keep the foam, fiberglass and all aspects about the plane. Just make it easier to build. Very little sanding. I believe it can be done.