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Jim,
I'm glad to see your enthusiasm, and I strongly encourage you to put it into action. And yes, if you can build a prototype much more easily than a well-finished final product, by all means do so.
Just a few comments on some of your steps.
2. If your boat-tail is as small and light as I think it will be, you may only need one or two ribs.
3. I'd love to see video of Insight tuft testing!
5. Your prototype will be cruder, and more angular, than a foam and fiberglass version, and the final version will be aerodynamically better. So if it works on the cardboard mockup, it's definitely going to work on the fiberglass version.
6. A professional paint job would be a nice touch. On Sunday, I painted a few panels on my Insight, and the good news is that they look fine from three feet away.
Keep us posted.
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