Do you want me to send you the SketchUp file? You can download SketchUp for free from Google. I might even try dropping the CarBEN model into a Boston street in Google Earth and see it in context...
I think the windows in the CarBEN would have to be Lexan or similar. Ideally, they would be low-E coated to reduce the heat gain, but that is later on.
The alternate to the bandsaw is an orbital jig saw -- fast cutting is needed since I have to make between 30 and 60 ribs (3"-6" apart!) and many of the cuts are 6-9 feet long.
The shape of the windshield is critical to the aerodynamics, and I don't think I can find anything even remotely close to what is required for this design.
New texture (obviously), and intake vent added (just under the front license plate). I added two of the 5'-9" tall figures from SketchUp for scale reference.
I made a few other subtle adjustments, including recessing the windows a bit so that they show up on the sections, and so they will be flush when the glazing is installed.
I'm leaning back to doing a fiberglass shell with steel tube chassis on the first one, because I am not confident that I could execute the structural mounting points, and reinforcing, etc. that a monocoque would require. So, the starting point is the same. The other snag is the band saw in my neighbor's wood shop is broken... I gotta' see if my friend building the airplane is done with his, or buy a used one. :-/