Lauan plywood for mods ? Aerohead please advise

[freebeard]

Here's how Howard Hughes did it:


and some sample cross sections they used:


Use the Luan to make an egg-crate form for 1/2 your compound curve shape, stretch burlap over it and cover with paiper mache (corrugated cardboard into the blender); then disassemble the egg-crate and reassemble it for the other half.

Consider PolyMetal. Thin aluminum skins with a core of recycled thermoplastic. It's probably no more expensive than marine plywood.